Abstract: The method and apparatus of the present invention includes a computer implemented injection molding configuring subsystem which enables a customer to interactively specify and design a system using a mix of parameters that the customer specifies and are manufacturing process determined. The configuring subsystem is connected to a computer network such as the Internet. The method and apparatus of the present invention further includes a computerized business and processing subsystem in communication with the configuring subsystem. The computerized business subsystem automatically provides a cost and schedule for a system configured by the configuring subsystem and additionally processes an order for the system. The processing subsystem automatically processes the customer's inputs and generates drawings for the configured system. Prior to receiving the customer's order, hot runner system components may be partially manufactured in a first phase and placed in inventory.

Abstract: An injection molding apparatus includes a manifold with a manifold melt channel, a nozzle with a nozzle channel and a valve pin with an outer surface in proximal to an inner surface of the nozzle channel. A valve pin melt channel is defined by and substantially coaxial to the valve pin. The valve pin melt channel communicates with the manifold melt channel when the valve pin is retracted and is restricted from the manifold melt channel when the valve pin is extended. A mold gate is open when the valve pin is retracted and is closed by a valve pin tip of the valve pin when the valve pin is extended. An outlet extends from a longitudinal portion of the valve pin melt channel to the surface of the valve pin adjacent to the valve pin tip and is in continuous communication with a well adjacent the mold gate.

Abstract: An injection molding apparatus includes a nozzle body, a valve pin, a nozzle tip, a seal piece, and a mold gate insert. The nozzle body has a melt channel. The valve pin is at least partially positioned in the melt channel. The valve pin has a first guidance and alignment structure thereon. The nozzle tip is connected to the nozzle body. The seal piece is connected to the nozzle body. The mold gate insert defines a gate and is in contact with the seal piece. The nozzle tip has a higher thermal conductivity than the nozzle body. The seal piece has a lower thermal conductivity than the nozzle body. The mold gate insert has a higher thermal conductivity than the seal piece. The mold gate insert includes a second guidance and alignment structure thereon that contacts the first guidance and alignment structure before the valve pin contacts the gate.

Abstract: An injection molding apparatus includes a manifold for delivering a melt stream of moldable material to a nozzle melt channel of a nozzle. A valve pin extends through the nozzle melt channel and is axially movable to selectively open a gate to allow communication with a mold cavity. A sensor is coupled to a forward end of the valve pin. The sensor may be a pressure sensor and/or temperature sensor in direct contact with the melt stream to provide pressure and/or temperature information to a controller.

Abstract: An apparatus and method for injection molding of molded products including a first cavity chamber for forming a seal liner, with the first cavity chamber having an outer edge, and a second cavity chamber for forming a shell, with the second cavity chamber having a center and being adjacent to the first cavity chamber. The injection molding apparatus and method also includes a first nozzle for a seal liner material positioned near the outer edge of, and in communication with, the first cavity chamber, and a second nozzle for a shell material positioned near the center of, and in communication with, the second cavity chamber. The injection molding apparatus and method further includes a mold core capable of being positioned in and moved between the first and second cavity chambers.

Abstract: A valve-gated nozzle for an injection molding machine includes an annular flow channel between downstream portions of a nozzle liner and a sealing and/or retaining device. The nozzle liner includes a first melt channel and one or more second melt channels for communicating a melt stream to the annular melt channel. The annular melt channel is formed between an inner surface of the downstream portion of the sealing and/or retaining device and an outer surface of the downstream portion of the nozzle liner. The annular melt channel may include a groove within at least one of the inner surface of the sealing/retaining device and the outer surface of the nozzle liner, such that the groove is in communication with an outlet of the second melt channel to thereby guide and/or blend the molten material within the annular melt channel to even and balance flow into a mold cavity.

Abstract: An injection molding apparatus includes a manifold having a manifold channel for receiving a melt stream of moldable material from a source and delivering the melt stream to a nozzle channel of a nozzle. A mold cavity communicates with the nozzle channel to receive the melt stream through the mold gate. A distribution assembly is located adjacent to the manifold. The distribution assembly includes at least one distribution member having a groove formed in an outer surface thereof and at least one conduit provided in the distribution member. The groove receives wiring from a heater of the nozzle and routes the wiring to a termination location or box. The conduit distributed fluid to various locations in the injection molding apparatus, such as actuation fluid for an actuator.

Abstract: The method and apparatus of the present invention includes a computer implemented injection molding configuring subsystem which enables a customer to interactively specify and design a system using a mix of parameters that the customer specifies and are manufacturing process determined. The configuring subsystem is connected to a computer network such as the Internet. The method and apparatus of the present invention further includes a computerized business and processing subsystem in communication with the configuring subsystem. The computerized business subsystem automatically provides a cost and schedule for a system configured by the configuring subsystem and additionally processes an order for the system. The processing subsystem automatically processes the customer's inputs and generates drawings for the configured system. Prior to receiving the customer's order, hot runner system components may be partially manufactured in a first phase and placed in inventory.

Abstract: A nozzle system is provided comprising a nozzle tip supported in a nozzle body with an alignment member. The alignment member has a connection for engaging a corresponding connection located on the nozzle body. The alignment member also has an aperture concentric with the sleeve that has a tapered engagement surface for contacting a tapered engagement surface on the nozzle tip. A first melt channel is defined through the nozzle body and a second melt channel is defined through the nozzle tip. The melt channel in the nozzle tip has a first section that extends along a first axis from an inlet, a second section that extends from the first section at an incline and a third section that extends from the second section parallel to and eccentric with the first axis. The resulting melt channel defines a straight through channel parallel to said first axis from said inlet to said opening.

Abstract: The invention relates to an injection molding apparatus including a mold block, a nozzle, a gating system and a slug heater. The mold block defines a mold cavity having a mold cavity inlet. The nozzle has a nozzle inlet. The nozzle inlet is fluidically connectable downstream from a melt source. The nozzle inlet is upstream from the mold cavity inlet. A melt flow passage extends from the nozzle inlet to the mold cavity inlet. The gating system includes a valve pin and an actuator. The valve pin is movable between an open position wherein melt flow is permitted into the mold cavity, and a closed position wherein the valve pin blocks the melt flow passage to prevent melt flow into the mold cavity. The actuator is operatively connected to the valve pin to move the valve pin between the open and closed positions.

Abstract: An injection molding system is disclosed. The system includes a multiple valve gated nozzle. The flow through each valve gate is determined by individually operated valve pins. Each valve pin is independently controlled by a separate actuation unit. In order to achieve a tight pitch between the valve pins, the actuation units are placed in a stacked configuration, with the valve pin controlled by the upper actuation unit passing through the lower actuation unit. The valve pin of the lower actuation unit is offset from a center of the upper actuation unit to allow for the unimpeded passage of the valve pin from the upper actuation unit through the lower actuation unit.

Abstract: An injection molding apparatus includes an injection piston that is slidable within a nozzle having a movable valve gate pin. The injection piston is movable from a retracted position to an extended position in order to force melt towards a mold cavity. A valve is located at a forward end of the piston to selectively block communication between a recess, which is provided in an outer wall of the piston adjacent the valve, and a melt chamber of the nozzle. Movement of the injection piston from the retracted position to the extended position causes the valve to close so that the predetermined volume of melt located below the valve is forced into the mold cavity, when the valve gate pin opens the mold gate.

Abstract: An injection molding apparatus including a manifold having a manifold melt channel, a nozzle having a nozzle melt channel, a slidable seal having seal melt channel located between the nozzle and the manifold melt channels, and a biasing element that provides sealing contact between the slidable seal and the manifold and nozzle to maintain a sealed melt path through the manifold, seal and nozzle melt channels.

Abstract: An injection molding apparatus for delivering a melt stream of moldable material to a mold cavity. A valve pin extends through a melt channel of the apparatus that is axially movable to control the melt stream within the melt channel and/or to selectively open a gate to allow communication with the mold cavity. A processing sensor is coupled to the valve pin and is axially movable therewith. By example, the processing sensor may be a pressure sensor and/or a temperature sensor for sensing processing condition(s) of the melt stream and providing sensed information to a controller.

Abstract: A nozzle system is provided for an injection molding machine. The nozzle system includes a nozzle tip that is removably connected to a nozzle body with a sealing and mounting sleeve element. The nozzle body includes a first connector for releasably connecting with a second connector defined on the sleeve. The sleeve element further includes an alignment bearing for engaging a bearing surface defined on the nozzle body for precisely locating the nozzle tip within the nozzle body along on a predetermined axis. Further embodiments of the invention provide a valve pin disposed in the nozzle body and nozzle tip. The valve pin includes a bearing surface for engaging a guiding surface defined on the second melt channel for aligning the end of the valve pin with a mold gate. Further embodiments also provide an integrally connected nozzle tip and sleeve element.

Abstract: An edge-gated injection molding apparatus includes a first, rear-mounted nozzle that is coupled to a manifold for receiving a melt stream therefrom. A second, front-mounted nozzle is coupled to the first nozzle by a nozzle link that is provided between the first and second nozzles. A plurality of gate seals are coupled to a forward end of the second nozzle. The gate seals receive melt from a plurality of melt passages and deliver the melt to a plurality of mold cavities through respective gates. The second nozzle is slidably removable from the first nozzle via the nozzle link to facilitate repair or replacement of the gate seals.

Abstract: An injection molding system includes a manifold and a valve gated hot runner nozzle. The gating mechanism includes an actuated valve pin, where the mold gate orifice is open when the valve pin is in a first position to allow melt to flow there through. The mold gate orifice is closed when the valve pin is in a second position to prevent melt from flowing there though. A flow control pin is disposed within the melt stream, either coaxially with the valve pin within the melt channel of the nozzle or within the manifold melt channel. The flow control pin has a head with a complementary geometry with that of the melt channel at a flow control surface. The flow control pin is raised and lowered by an actuation mechanism to constrict or release the flow of the melt stream independent from the movement of the valve pin.

Abstract: This invention teaches a hot runner injection molding apparatus for co-injecting at least two different materials into a mold cavity. A pin valve gated hot runner nozzle includes separate melt channels for each material and a melt chamber for accurately metering one of the materials. The melt chamber is in communication with an injection piston. The controlled movement of the valve pin and of the injection piston insures that the desired amount of a first and at least a second material is injected into the mold cavity. Depending of the composition and the processing window of the materials, the co-injection hot runner nozzle is in communication with either a single or multiple manifolds.

Abstract: A valve pin bushing for a valve gated injection molding apparatus having, a back plate, a valve pin bushing, and a manifold, with axially aligned respective valve pin bores. The valve pin bushing includes a back plate contacting surface and an opposite manifold contacting surface for bearing against the back plate and manifold, respectively. The back plate contacting surface has a surface area larger than a surface area of the manifold contacting surface to draw heat from the valve pin bushing to the cooler back plate. An air gap, which may be sealed by an optional sealing portion, is formed where the flange is spaced away from a central portion of the valve pin bushing near the manifold. The valve pin bushing also includes a tubular member for positioning within the manifold valve pin bore, which defines a portion of the manifold melt passageway.

Abstract: An injection molding apparatus has a manifold and a plurality of first and second adjustable manifold blocks. The second manifold blocks are in fluid communication and are directly connected to a hot runner nozzle. The second manifold blocks are coupled to the first manifold blocks via connector devices. These connector devices contain a melt channel and allow the second manifold blocks and therefore the hot runner nozzles to be rotated relative to the first manifold blocks around at least two axes. This allows the nozzles to be positioned in front of mold gates that are located at variable elevations with respect to the manifold.