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: The present invention provides an electrically heated nozzle for injection molding which is insulated to prevent conduction of electricity and loss of thermal transmission to the casing, with first and second electric heaters which can operate independently or simultaneously to heat the melt channel of the nozzle.

Abstract: A stack injection molding apparatus has first and second arrays of valve gate injection nozzles and separate mechanisms for independently actuating the nozzles of each array. A separate reciprocating yoke plate engages the valve pins of each nozzle array, and is actuated by either one centrally located actuator or a pair of symmetrically located actuators.

Abstract: A system and method including an injection molding system (e.g., nozzle) having a nozzle body with a heater holding portion that receives a heating device that is releasably secured in the heater holding portion. The nozzle has at least one flat or planar outer surface and can be made from a high wear and high pressure resistant material (e.g., Aermet). A slot of the heater holding portion and the heating device can be of complimentary geometries, such as rectangular shaped, wedge shaped, or any other shape. The heating device can include a holding device having receiving areas. Each receiving area can receive a respective heater that can be removed from the nozzle body. The nozzle body is provided with a clamping mechanism to insure an intimate contact between the heater holding portion and the heater device.

Abstract: A guide for a manifold plug of an injection molding apparatus comprises a guide body projecting from an inner wall of the manifold plug diametrically opposing an inlet of a manifold plug channel formed in the manifold plug. The inlet is aligned with a manifold channel of a manifold. The outlet of the manifold plug channel is aligned with a nozzle channel of a nozzle. The inlet is at an angle to the outlet. A guide surface is provided on the guide body for abutting a downstream portion of a valve pin extending into the manifold plug channel. The guide also facilitates flow of a melt stream of moldable material through the manifold plug channel.

Abstract: The present invention relates to an injection molding appartus having a linear actuator for a control valve with a position sensor and a cooling assembly, wherein the position sensor is integrated into or positioned proximal to the cooling assembly.

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 nozzle (e.g., a flat nozzle, an asymmetric nozzle, a micro nozzle, a flat micro nozzle, etc.) is configured to make injection molded components. The nozzle includes a nozzle body, a heater associated with the nozzle body, a melt channel running through the nozzle body configured to allow melt material flow, and a thermally conductive device located inside the nozzle body. The thermally conductive device can be configured to produce an even heat profile along an entire length of the melt channel. The nozzle body can be symmetrical or asymmetrical and can be made of a different, less thermally conductive material, than the thermally conductive device. The thermally conductive device can be used to balance a heating profile of the nozzle to produce consistency in melt material viscosity and speed throughout a micro nozzle channel.

Abstract: A system and method for making molded parts that include one or more planar heaters coupled, secured, or releaseably secured to one or more sides of each of the one or more nozzles. The releasably secure coupling allows heater device to be visually inspected, tested, removed, and/or replaced. The planar heater device can have a support device patterned with an electrical resistive path. The electrical resistive path can include any pitch or number of electrical resistance lines, such that a longitudinal uniform heat profile is generated along a melt flow channel of the one or more nozzles when the nozzles are in use.

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: 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.

Abstract: The present invention provides an electrically heated nozzle for injection molding which is insulated to prevent conduction of electricity and loss of thermal transmission to the casing, with an electric heater and sensor that are wrapped around substantially the same portion of a melt channel of the nozzle.

Abstract: A nozzle end is provided for removable mounting to a nozzle body for use in multiple-tipped molding applications such as edge-gated systems. The nozzle end is made of a highly thermally conductive material and is preferably inserted at least partially inside the forward end of the heated nozzle body. Removable nozzle tips are insertable in the front end of the nozzle end.

Abstract: A mold gate insert includes a mold gate insert body, which is comprised of a material having a high thermal conductivity, and a thermal insulation element, which is nested in the mold gate insert body. The thermal insulation element is provided to abut a nozzle seal and align the nozzle with a mold gate. The amount of heat transferred from the nozzle to the mold gate insert is reduced by the thermal insulation element.

Abstract: The present invention provides an electrically heated nozzle for injection molding which is insulated to prevent conduction of electricity and loss of thermal transmission to the casing, with first and second electric heaters which can operate independently or simultaneously to heat the melt channel of the nozzle.

Abstract: An injection molding apparatus and method for multi-layer molding of preforms and closures has a central melt channel, an annular melt channel radially spaced from the central melt channel, and an annular ring channel surrounding the central melt channel. The central melt channel has a first portion for flow of a first material, a second portion for flow of the first material and a second material, and a flow extension connecting the first portion and the second portion. The flow extension has a flow opening in communication with the annular ring channel for flow of the second material. The apparatus and method also include a cavity for receiving flow of the first material and the second material from the central melt channel, and for receiving flow of the first material from the annular melt channel. In addition, the apparatus and method include a melt passage having a first melt portion in communication with the central melt channel, and a second melt portion in communication with the annular melt channel.

Abstract: An injection molding apparatus and method for multi-layer molding of preforms and closures has a central melt channel, an annular melt channel radially spaced from the central melt channel, and an annular ring channel surrounding the central melt channel. The central melt channel has a first portion for flow of a first material, a second portion for flow of the first material and a second material, and a flow extension connecting the first portion and the second portion. The flow extension has a flow opening in communication with the annular ring channel for flow of the second material. The apparatus and method also include a cavity for receiving flow of the first material and the second material from the central melt channel, and for receiving flow of a third material from the annular melt channel.

Abstract: The present invention provides an electrically heated nozzle for injection molding which is insulated to prevent conduction of electricity and loss of thermal transmission to the casing, with first and second thermocouples for sensing temperature of the nozzle, the two thermocouples are independent so they can act either independently or simultaneously to sense temperature conditions in the melt channel of the nozzle.

Abstract: A locking mechanism for locking a valve pin of a nozzle of an injection molding apparatus in an extended position includes a generally oblong detent coupled to a pin. The pin extends through an aperture located at a first end of the detent to secure the detent to an inner wall of a recess, which is located adjacent the piston-receiving cavity of the valve pin. The detent is pivotable about the pin to rotate a second end of the detent into abutment with a return surface of the piston to restrict movement of the valve pin.

Abstract: Injection molding hot runner apparatus having a cooled mold core with an elongated body portion with a front portion or head. A cooling tube extends centrally in body portion of the mold core. A cooling fluid circuit extends from the open front end of the cooling tube outwardly through a number of spaced radial bores. Each radial bore connects to an L-shaped duct leading back to a cylindrical space around the cooling tube.