Abstract: An injection molding system is disclosed that utilizes a melt channel wherein at least a portion of the melt channel has a noncircular cross-section for balancing shear in a melt stream of moldable material that flows therethrough. The noncircular cross-section of the melt channel portion may be, for e.g., capsule-shaped, extended egg-shaped, oval, teardrop-shaped, or peanut-shaped. A flow splitter is also disclosed that is positioned offset from a central axis of an upstream melt channel to protrude between inlets of respective downstream melt channels, where the upstream melt channel splits into the downstream melt channels, to thereby create a narrower inlet into one of the downstream melt channels and a wider inlet into the other of the downstream melt channels.

Abstract: An actuator is disposed between a back plate and a manifold and is connected to a valve pin. A nozzle flange, locating ring, or pressure disc can transmit a first load between the manifold and a mold plate. A pressure disc can be disposed between the actuator and the back plate. The pressure disc transmits a second load between the back plate and the manifold through the actuator.

Abstract: An auxiliary injection unit is disclosed that has an extruder barrel and extruder screw integrated within an injection molding system. The extruder barrel and extruder screw are contained within a mold plate of the injection molding system with a drive mechanism of the auxiliary injection unit being external thereof. A melt stream emanating from the extruder barrel of the auxiliary injection unit is in selective fluid communication with either a melt channel of a manifold providing melt thereto during an injection cycle or with a discharge channel of a melt discharge tube for purging melt. A melt diverter component receives the melt stream from the extruder barrel and includes a shuttle valve slidably positioned therein that is operated to selectively divert the melt stream produced by the auxiliary injection unit to either the melt channel of the manifold or the discharge channel of the discharge tube.

Abstract: An injection molding apparatus is disclosed having an actuated part that is movable in forward and rearward directions with a magnetic valve pin coupling attached thereto. A valve pin for opening and closing a mold gate is coupled to the magnetic valve pin coupling to be movable with the actuated part. When the actuated part is moved in an opening stroke direction and the valve pin experiences a stopping force, the magnetic valve pin coupling permits the valve pin to become decoupled from the actuated part to prevent continued movement of the valve pin with the actuated part.

Abstract: An injection molding apparatus, such as a hot runner or hot half, includes a manifold having a manifold channel and a nozzle having a nozzle channel. The nozzle is coupled to the manifold, and the manifold channel and the nozzle channel are in communication to define a flow channel. A valve pin bushing has a flow restrictor disposed in the flow channel on an upstream side of the valve pin bushing. A moveable valve pin extends through a bore of the valve pin bushing.

Abstract: There is set forth a system comprising an injection molding assembly mold and a processing circuit. The mold can have a stationary section and a moveable section. The stationary section can have a channel assembly and one or more nozzle. The processing circuit can comprise one or more processor, a communication interface, and a memory including a volatile memory and a non-volatile memory. The processing circuit can be mounted to the stationary section or the moveable section in a manner that the processing circuit can be supported in a fixed position relative to the stationary section or the moveable section. The mold can further comprise one or more sensor unit, each sensor unit including one or more sensor.

Abstract: A runnerless nozzle for an injection molding apparatus includes a bracing component having an internal space and a lateral bore, a nozzle tip extending from the internal space through the lateral bore of the bracing component, and a securing component installable in the internal spaced of the bracing component. At least one of the bracing component and the securing component defines a lateral channel in communication with and upstream channel for delivering molding material to the nozzle tip. The securing component includes an angled surface for wedging a likewise angled surface of the nozzle tip to engage the nozzle tip with the bracing component when the securing component is installed in the bracing component.

Abstract: An injection molding apparatus includes an inlet component, a plurality of nozzles, and a plurality of hoses, each of which is not heated. The hoses are connected between outlets of the inlet component and respective molding material inlets of the nozzles for conveying molding material from the inlet component to the nozzles. Hoses may also be connected between a rail plate and the nozzles for delivering cooling fluid or actuation fluid for an actuator to and from the nozzles. The nozzles may be fastened to a mold plate of the injection molding apparatus, such as by a threaded bushing. A heated insert may at least partially define the mold cavity to heat molding material in the mold cavity.

Abstract: There is provided a system for use in performance of injection molding operations, wherein the system can include a plurality of injection molding assembly components. In one embodiment, the system can be operative so that various information respecting components of the system can be recorded within a component database. The component database can be a computer implemented database and in one embodiment can be utilized to output information that indicates past and/or present conditions prevailing within the system.

Abstract: A method for taking a nozzle of a valve gated runner apparatus includes releasably attaching a valve pin to a movable part of an actuator for moving the valve pin between an open position and a closed position and detaching the valve pin from the actuator by moving the movable part of the actuator towards the open position when the valve pin is immobilized. The valve pin and the movable part valve pin may be releasably attached by a magnetic force. The step of detaching the valve pin from the actuator may be accomplished by overcoming the magnetic force. A valve pin plate can be provided for a plurality of valve pins to be releasably attached to the actuator.

Abstract: A valve pin that accommodates side loading for use in a valve-gated nozzle of a hot runner injection molding system is disclosed. The valve pin is operably coupled at a rearward end to an actuating mechanism and includes a shaft that extends through the system such that a forward end thereof engages with a mold gate of a mold cavity. The valve pin shaft has a region forward of the rearward end thereof that accommodates side loading under operating conditions. The region may be a slidable or rotatable interface configured to provide lateral or angular movement between upstream and downstream portions of the valve pin shaft under side loading conditions or may be configured to provide increased flexibility to the valve pin shaft within the region to permit deflection of the valve pin under side loading conditions.

Abstract: There is set forth herein a system having an injection molding assembly mold including a stationary section and moveable section, the stationary section having a channel assembly, one or more nozzle and a mold cavity, the mold further having a sensor unit array, the sensor unit array comprising one or more sensor unit. The system can include one or more processing circuit that utilizes an output of the one or more sensor unit for determining a condition prevailing within the injection molding assembly.

Abstract: An injection molding apparatus is disclosed having an actuated part that is movable in forward and rearward directions with a magnetic valve pin coupling attached thereto. A valve pin for opening and closing a mold gate is coupled to the magnetic valve pin coupling to be movable with the actuated part. When the actuated part is moved in an opening stroke direction and the valve pin experiences a stopping force, the magnetic valve pin coupling permits the valve pin to become decoupled from the actuated part to prevent continued movement of the valve pin with the actuated part.

Abstract: A method and apparatus of controlling commencement of an injection of a melt stream of moldable material from an auxiliary injection unit. A sensor is placed in an injection molding system to sense a condition related to an injection of a first melt stream of a first moldable material provided by a primary injection unit. Commencement of a second melt stream of a second moldable material from the auxiliary injection unit is initiated upon the sensed condition related to the injection of the first melt stream being detected at a preselected value. The sensed condition may be a pressure, velocity or temperature of the first melt stream as provided by a direct sensor, a force or strain on a hot runner component as provided by an indirect sensor or the occurrence of a function of the injection molding system as provided by a functional sensor.

Abstract: A cavity insert for a mold stack is disclosed, the cavity insert being dimensioned to define a continuous annular cavity insert cooling chamber. The cavity insert also provides a first and second decompression chamber in fluid communication with each end of the cavity insert cooling chamber. Also disclosed is a chamber extension feature in fluid communication with the cavity insert cooling chamber to promote cooling in the downstream region of the cavity insert.

Abstract: An injection molding apparatus is disclosed having a single level manifold that utilizes a melt splitter. The manifold defines an inlet and a plurality of outlets with at least one upstream melt channel and a plurality of downstream melt channels that are situated between the inlet and the plurality of outlets. The upstream melt channel branches into the plurality of downstream melt channels with the upstream melt channel and each of the downstream melt channels longitudinally extending in the same plane. The melt splitter is at least partially positioned within the upstream melt channel where the upstream melt channel intersects with the plurality of downstream melt channels. The melt splitter divides a melt flow received from the upstream melt channel into substantially equal volumes and then directs each of the substantially equal volumes into a respective one of the plurality of downstream melt channels.

Abstract: A nozzle body defines an upstream channel. A downstream bracing portion has a lateral bore. A nozzle tip extends laterally through the lateral bore of the bracing portion and has a sealing surface for engaging a gate component that defines a mold gate. The runnerless nozzle further includes a securing component inserted into the bracing portion to hold the nozzle tip against the bracing portion. The bracing portion or the securing component defines a lateral channel in communication with the upstream channel for delivering molding material to the nozzle tip. The nozzle tip can be removed by removing the securing component.

Abstract: A nozzle body defines an upstream channel. A downstream bracing portion has a lateral bore. A nozzle tip extends laterally through the lateral bore of the bracing portion and has a sealing surface for engaging a gate component that defines a mold gate. The runnerless nozzle further includes a securing component inserted into the bracing portion to hold the nozzle tip against the bracing portion. The bracing portion or the securing component defines a lateral channel in communication with the upstream channel for delivering molding material to the nozzle tip. The nozzle tip can be removed by removing the securing component.

Abstract: One or more nozzles define separate nozzle channels. The nozzles are coupled to a manifold, so that each of the nozzle channels communicates with a different mold gate. A molding material distribution insert is coupled to the manifold and has a body defining a distribution channel and a plurality of drop channels equal in number to the nozzle channels. The distribution channel is an open distribution channel formed on an outer surface of the body and enclosed by the manifold. The drop channels intersect the distribution channel and exit the body at a different one of the nozzle channels. A valve pin bushing can extend into the drop channels. Valve pins can extend from actuators, through the valve pin bushing and the drop channels, and to the mold gates. A valve pin holder can be coupled to the actuator and coupled to heads of the valve pins.

Abstract: A nozzle body defines an upstream channel. A downstream bracing portion has a lateral bore. A nozzle tip extends laterally through the lateral bore of the bracing portion and has a sealing surface for engaging a gate component that defines a mold gate. The runnerless nozzle further includes a securing component inserted into the bracing portion to hold the nozzle tip against the bracing portion. The bracing portion or the securing component defines a lateral channel in communication with the upstream channel for delivering molding material to the nozzle tip. The nozzle tip can be removed by removing the securing component.