Abstract: A two stage spring pack device comprising a nozzle or back up insulator, surrounded by a first stage spring for applying an initial force, and a plurality of Belleville springs to exert a secondary force against a thermally expanding hot runner manifold in an injection molding system, precludes resin leakage between a manifold and nozzle or between mating manifolds in a cross manifold system. The first stage spring imparts a relatively low initial force against the hot runner components while the system heats up from ambient temperature to prevent plate bowing and component hobbing, until it is fully compressed, at which point a subsequently larger sealing force is exerted by the constant force Belleville springs to prevent leakage between the mating components at operating temperature and injection pressure.

Abstract: An injection molding machine is provided, including a nozzle assembly having a channel for conveying a fluid. At least one cavity insert is removably mounted within a cavity plate, the at least one cavity insert defining a mold cavity, and a first portion of a gate for communicating the fluid between the nozzle assembly and the mold cavity. A gate insert defines a receptacle for the nozzle assembly, and further defining a second portion of the gate. The gate insert is floatably retained between the nozzle assembly and the at least one cavity insert. Preferably, the gate insert is retained by a gate insert plate that is disposed between the cavity plate and the nozzle assembly.

Abstract: The electric service load of a machine having at least one electric heater and at least one electric motor may be managed as follows. Where the electrical service load of the machine exceeds a threshold, which may result from transient in-rush current attendant upon start-up of an electric motor, or where this load is expected to exceed the threshold, at least one of the heaters may be de-energized. The heater may remain de-energized either for a pre-determined period of time or until the electrical service load falls below a further threshold.

Abstract: A flexible plate system for a hot runner assembly includes a backing plate; a manifold plate detachably connected to the backing plate; a manifold positioned between the backing plate and the manifold plate and having at least one nozzle associated therewith; and wherein the manifold plate has at least one plate slot that allows the nozzle to extend through the manifold plate and having at least a first lateral dimension substantially larger than the outside diameter of the nozzle.

Abstract: A flexible plate system for a hot runner assembly includes a backing plate; a manifold plate detachably connected to the backing plate; a manifold positioned between the backing plate and the manifold plate and having at least one nozzle associated therewith; and wherein the manifold plate has at least one plate slot that allows the nozzle to extend through the manifold plate and having at least a first lateral dimension substantially larger than the outside diameter of the nozzle. The manifold plate and the backing plate may be configured to have at least one manifold plate cavity and at least one backing plate cavity to accept at least one nozzle insert and at least one piston cylinder insert respectively, the nozzle insert having a nozzle bore or a plurality of insert slots therethrough for installation of the nozzle, and the piston cylinder insert having a cylinder bore for a piston cylinder.

Abstract: A hot runner system having a melt distribution system that is reusable and reconfigurable to vary drop or nozzle locations to meet various design requirements. The melt distribution system includes a melt distributor in fluid communication with a melt source, at least one melt conduit in fluid communication with the melt distributor, and at least one nozzle in fluid communication with the at least one melt conduit. The hot runner system also includes a backing plate; a manifold plate detachably connected to the backing plate; a melt distribution system positioned between the backing plate and the manifold plate and having at least one nozzle associated therewith. The hot runner system may be configured and reconfigured to accommodate various drop or nozzle locations.

Abstract: An injection molding machine is provided, including a nozzle assembly having a channel for conveying a fluid. At least one cavity insert is removably mounted within a cavity plate, the at least one cavity insert defining a mold cavity, and a first portion of a gate for communicating the fluid between the nozzle assembly and the mold cavity. A gate insert defines a receptacle for the nozzle assembly, and further defining a second portion of the gate. The gate insert is floatably retained between the nozzle assembly and the at least one cavity insert. Preferably, the gate insert is retained by a gate insert plate that is disposed between the cavity plate and the nozzle assembly.

Abstract: There is provided a stress-reducing device and a method of using same. The stress reducing device comprises an insert positionable, in use, proximate to an area of a fluid-carrying conduit that experiences increased tensile stress concentration, the insert being configured to apply, in use, compressive force onto the area.

Abstract: Method whereby coinjection molding shooting pot actuation structure is configured to be installed in a coinjection hot runner with a coinjection nozzle, the coinjection nozzle having at least two melt channels ending at the same gate. The shooting pot is preferably disposed in one of a mold cavity half and a mold core half. A shooting pot piston is configured to discharge a melt from the shooting pot. A transmission structure is configured to (i) extend through one of the mold cavity half and the mold core half, and (ii) to transmit a force to the shooting pot piston. Actuation structure is disposed on the opposite side of the mold cavity half from the coinjection hot runner, and is configured to provide the force to the transmission structure. This configuration conserves space in the mold.

Abstract: Apparatus and method whereby coinjection molding shooting pot actuation structure is configured to be installed in a coinjection hot runner with a coinjection nozzle, the coinjection nozzle having at least two melt channels ending at the same gate. The shooting pot is preferably disposed in one of a mold cavity half and a mold core half. A shooting pot piston is configured to discharge a melt from the shooting pot. A transmission structure is configured to (i) extend through one of the mold cavity half and the mold core half, and (ii) to transmit a force to the shooting pot piston. Actuation structure is disposed on the opposite side of the mold cavity half from the coinjection hot runner, and is configured to provide the force to the transmission structure. This configuration conserves space in the mold.

Abstract: Apparatus and method whereby coinjection molding shooting pot actuation structure is configured to be installed in a coinjection hot runner with a coinjection nozzle, the coinjection nozzle having at least two melt channels ending at the same gate. The shooting pot is preferably disposed in one of a mold cavity half and a mold core half. A shooting pot piston is configured to discharge a melt from the shooting pot. A transmission structure is configured to (i) extend through one of the mold cavity half and the mold core half, and (ii) to transmit a force to the shooting pot piston. Actuation structure is disposed on the opposite side of the mold cavity half from the coinjection hot runner, and is configured to provide the force to the transmission structure. This configuration conserves space in the mold.

Abstract: An improved nozzle for high melt pressure applications includes an inner body portion having a melt channel, the inner body portion having an inlet face and a melt outlet; an outer body portion having a seal face, with the outer body portion inducing a compressive force on the inner body portion at least during operation of the nozzle; the plane of the inlet face of the inner body portion intersecting the outer body portion, resulting in no part of the inner body portion extending beyond the seal face of the outer body portion; and the inner and outer body portions having different relative thermal conduction and expansion coefficients.

Abstract: Coinjection molding system control apparatus and method preferably includes flow control structure and/or steps configured to reduce pressure on a second melt, preferably causing a relatively small portion of a first melt to flow from a distal portion of a first melt channel in the coinjection nozzle into a distal end of a second melt channel in the coinjection nozzle. This prevents substantial amounts of the second melt from being dragged into the mold cavity when the next shot of the first melt is injected.

Abstract: A method of manufacturing a variety of injection molding hot runner system components using two materials. Blanks for portions of the components are formed of each material and fused, preferably by electron beam welding, then the component having the two portions is machined to its final configuration. Components made with this process include nozzle tip components such as tips, tip retainers, and tip inserts, as well as manifold bushings, valve stems and nozzle housings.

Abstract: A manifold plug for a hot runner manifold for an injection molding system has a generally circular shaped outer surface in which is disposed a channel extending along at least an arc of the generally circular shaped outer surface of the manifold plug. The manifold plug is configured for insertion into a generally circular shaped opening in the hot runner manifold and serves to fluidly interconnect at least first and second hot runner passageways which are otherwise unconnected and which terminate in the generally circular opening in the hot runner manifold. The channel in the generally circular shaped outer surface of the manifold plug is configured for fluidly connecting at least first and second unconnected resin passageways.

Abstract: A hot runner system includes a having a cavity. Melt is fed from a source of melt into the cavity, and a valve isolates melt in the cavity from melt in the source. A plunger within the cavity is driven forward to inject melt in the cavity into a mold cavity at high pressure without significantly increasing the pressure of melt in the source. The plunger optionally functions as both the plunger and the valve by opening and closing communication between the cavity and the manifold as it is rotated.

Abstract: A cam and cam follower apparatus translates linear cam bar movement to perpendicular valve stem actuation in an injection molding system. The cam bars reciprocate up and down on linear bearing rails such that an actuation plate, fitted with a plurality of valve stems, is cycled normal to the direction of the cam bar movement via cam followers traveling within cam slots in the cam bars. The cam slots in the cam bars are profiled such that the cam followers affect the speed and force at which the valve stems travel while at the same time reducing frictional effects and their associated power requirement. The cam followers of the valve stem actuation plate travel in cam slots in the cam bars from a valve stem forward position, to a valve stem retracted position and ultimately, the entire actuation plate may be removed from the cam bars for maintenance via open ended slots in the cam bars.

Abstract: Method and apparatus for controlling a vent gap in a mold for an injection molding machine are provided, and include an active material insert configured to be regulate the degree of opening of the vent gap. The active material insert is configured to be actuated in response to signals from a controller, so as to selectively block the opening of the vent gap during the molding process. Wiring structure is coupled to the active material insert, and is configured to carry the actuation signals. Melt flow sensors may also be provided to aid in regulating the vent gap, and may be connected to the controller in order to provide real-time closed loop control over the operation of the vent gap. Preferably, the methods and apparatus are used as part of a system for controlling the flow of melt within a mold cavity.

Abstract: Molding system for use with a mold having stationary mold portion and movable mold portion, molding system comprising: stationary platen configured to support stationary mold portion; movable platen configured to be movable relative to stationary platen, and movable platen configured to support movable mold portion; and extruder, including: barrel defining channel extending through barrel; liner received in channel, liner defining first conically-shaped end; machine nozzle connecting with the mold; and barrel head fixedly connected with barrel, barrel head fixedly connected with machine nozzle so that molten molding material is conveyable from barrel to cavity defined by the mold, barrel head defining passageway extending through barrel head, barrel head defining second conically-shaped end exiting the passageway, second conically-shaped end mated with the first conically-shaped end of the liner so that channel and passageway are aligned with each other.

Abstract: A system and method configuring a machine controller to control a selected piece of molding machine equipment may comprise presenting to a user a first set of pieces of molding machine equipment, presenting to the user a set of graphical user interface (GUI) formats associated with a second set of pieces of molding machine equipment by at least one manufacturer of the second set of pieces of molding machine equipment, selecting at least one piece of molding machine equipment to be controlled by the molding machine control apparatus from the first set of pieces of molding machine equipment, selecting a GUI format from the set of GUI formats, and configuring a GUI of the machine controller to control the selected piece of molding machine equipment based on the selected GUI format.