Abstract: An injection molding melt distribution manifold and method of making it with a melt passage extending from a single inlet to a plurality of outlets. The melt passage has a branching portion formed by machining matching grooves in opposing surfaces of two steel plates and then integrally brazing them together. The manifold has an embedded electrical heating element received in a channel formed by two other matching grooves in the opposing surfaces of the two plates. The channel is then integrally filled with nickel by heating under a partial vacuum. The electrical heating element which extends around and is in or near the same plane as the branching portion of the melt passage to ensure rheological and thermal balance of the melt flowing therethrough.

Abstract: An injection molding nozzle with an electrical heating element having a terminal for connecting external leads with an insulative connector formed of ceramic material. The insulative connector has a pair of spaced parallel longitudinal bores in which the outer end portions of the heating element conductive wires and the bared inner end portions of the external leads overlap and are secured together by set screws. A steel cap fits over the ceramic connector to protect it and provide the combination with sufficient structural strength to prevent damage during use. A resilient seal mounted between the ceramic connector and the cap also prevents damage to the connector and prevents moisture entering into the connector.