Abstract: The present invention generally relates to an injection molding apparatus, comprising a manifold including a plurality of manifold channels and a plurality of nozzles. Each of the nozzles defines a nozzle channel in fluid communication with one of the manifold channels and including a plurality of nozzle bodies coupled in tandem by a removable and secure connection. The nozzle bodies include at least a upstream nozzle body and a downstream nozzle body. The upstream nozzle body has an upstream end adjacent said manifold channel, and the downstream nozzle body has a downstream end adjacent a mold plate. A removable nozzle tip is retained in a downstream end of each downstream nozzle body. The nozzles also include a plurality of heaters, wherein at least one heater is embedded into each nozzle body.

Abstract: A seal is provided between a nozzle and a manifold. The seal provides a melt channel between an outlet of the manifold and a nozzle channel. The seal has higher thermal expansion coefficient than both the nozzle and the manifold to provide an improved seal between the manifold and the nozzle when the injection molding apparatus is at an operating temperature.

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: A nozzle is provided for an injection molding apparatus. The nozzle includes a nozzle body, a heater, a tip, a tip surrounding piece. The nozzle body defines a nozzle body melt passage, which has an inlet that is adapted to be downstream from and in communication with a melt source. The heater is connected to said body for heating melt in said nozzle body melt passage. The tip defines a tip melt passage that is downstream from and in communication with said nozzle body melt passage. The tip melt passage has an outlet that is upstream from a gate in a mold component. The tip includes a tip sealing surface. The tip surrounding piece includes a first tip surrounding piece sealing surface. The first tip surrounding piece sealing surface and said tip sealing surface are separated by a gap. The gap is sized to inhibit the flow of melt between said first tip surrounding piece sealing surface and said tip sealing surface.

Abstract: An injection molding nozzle with a tip portion in the gate area of the mold that has a wear-resistant diamond-type coating. The surface of the tip melt channel that delivers melt to the gate area may also comprise a diamond-type coating. Nozzle seal surfaces in the gate area may also comprise a diamond-type coating. The enhanced harness, smoothness and thermal conductivity of these coated surfaces results in higher quality molded parts, and easier to clean molding equipment that has a longer service life.

Abstract: A valve pin actuating mechanism including a valve pin guiding element for connection to a valve pin, a linkage element and an actuator. The valve pin guiding element has a sliding surface for sliding within a channel, and first and second engagement surfaces. The linkage element has first and second arms, which have opposing, inwardly facing arcuate engagement surfaces for engaging the valve pin guiding element. The linkage element is moved by the actuator.

Abstract: A nozzle for an injection molding apparatus is provided. The nozzle includes a nozzle body, a heater and a first gap seal surface. The nozzle body defines a nozzle body melt passage, that is adapted to be downstream from and in fluid communication with a melt source, and upstream from and in fluid communication with a gate into a mold cavity in a mold component. The heater is thermally connected to the nozzle body for heating melt in the nozzle body melt passage. The first gap seal surface is positioned on a structure that is connected at least indirectly to the nozzle body. The first gap seal surface is adapted to be separated by a gap with respect to a second gap seal surface on the mold component. The gap is sized to inhibit the flow of melt between the first gap seal surface and the second gap seal surface.

Abstract: An improved melt distribution system and method is provided for a multi-level stack mold having three or more moving platens. The injection machine communicates with a bifurcated sprue bar for providing pressurized melt through the first moving platen to a central distribution manifold in the second moving platen. From the central distribution manifold, the flow of pressurized melt is distributed to the first and third platens for transfer to a plurality of mold cavities.

Abstract: An injection molding apparatus that includes a nozzle having a nozzle channel, a mold cavity in communication with the nozzle channel of the nozzle for receiving a melt stream of moldable material from the nozzle channel through a mold gate; and a valve pin that is axially movable through the nozzle channel of the nozzle between a first retracted position in which the valve pin closes the mold gate to block melt flow between the nozzle channel and the mold cavity, an extended position in which an end portion of the valve pin extends through the mold gate and into the mold cavity, and a third retracted position in which the end portion of the nozzle pin is withdrawn from the mold cavity into the nozzle and spaced apart from the mold gate thereby opening the mold gate.

Abstract: A seal is provided between a nozzle and a manifold. The seal provides a melt channel between an outlet of the manifold and a nozzle channel. The seal has higher thermal expansion coefficient than both the nozzle and the manifold to provide an improved seal between the manifold and the nozzle when the injection molding apparatus is at an operating temperature.

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: An improved melt distribution system and method is provided for a multi-level stack mold having three or more moving platens. The injection machine communicates with a bifurcated sprue bar for providing pressurized melt through the first moving platen to a central distribution manifold in the second moving platen. From the central distribution manifold, the flow of pressurized melt is distributed to the first and third platens for transfer to a plurality of mold cavities.

Abstract: A valve bushing assembly for use in an injection molding apparatus is provided. The injection molding apparatus includes a manifold block, a valve pin, and an actuator block. The manifold block has at least one melt channel therein. The manifold block has an exterior surface that faces the actuator block, and has a manifold pass-through extending from the exterior surface to the at least one melt channel. The manifold pass-through has a manifold sealing surface therein. The manifold pass-through permits the valve pin to pass therethrough. The actuator block has an actuator attached thereto, that is operatively connected to the valve pin. The valve bushing assembly includes a bushing and a spacer. The bushing is adapted to be received in the manifold pass-through. The bushing has a bushing pass-through that is adapted to align with the manifold pass-through and is adapted to slidably receive the valve pin.

Abstract: An injection molding apparatus is provided. The injection molding apparatus includes a manifold having at least one runner that receives melt from a melt source, a heat source for heating the melt, a nozzle in fluid communication with the manifold, and a mold component having a mold cavity for receiving melt from the nozzle. The nozzle includes a nozzle body having a melt passage therethrough, a nozzle tip having a tip melt passage therethrough, wherein the tip melt passage is in fluid communication with the melt passage of the nozzle body, and a tip surrounding piece that is removably coupled to the nozzle body. The tip surrounding piece retains the nozzle tip in position with respect to the nozzle body. The tip surrounding piece is preferably formed of a material that has a thermal conductivity that is equivalent to that of the nozzle tip.

Abstract: A heater assembly for an injection molding apparatus comprises a heater sleeve having a threaded inner surface for engaging a threaded outer surface of a nozzle body of a nozzle or a threaded surface of a mold manifold. A clamping element such as a lock nut or a spring is provided adjacent the heater sleeve. The lock nut and/or the spring abuts the heater sleeve to force the threaded inner surface of the heater sleeve into contact with the threaded outer surface of the nozzle body. This removable clamped heater assembly operates regardless of the temperature of heater.

Abstract: A neuromuscular monitoring system comprises at least one neurostimulator to apply muscle-activating stimulation signals to a patient's body via at least one electrode, and at least one pressure waveform sensor to detect pressure waveform signals produced by a patient's muscle in response to the applied stimulation signals. The detected pressure waveform signals are processed and data related to these detected pressure waveform signals are displayed. A method for neuromuscular monitoring using pressure waveform sensors is also described.

Abstract: A valve pin assembly for an injection molding apparatus comprising a valve pin capable of movement up and down in a nozzle to open and close a ring gate. An annular passage is created through the nozzle and is unobstructed and without restriction at all points up to and through the ring gate, permitting melt to flow freely to the gate and, depending on the position of the valve pin, into the mold cavity. The valve pin has a head with a diameter larger than the valve pin shaft for selectively closing the gate. The ring gate channel diameter is larger than the melt channel diameter to permit parts with large apertures therein to be formed.

Abstract: A two-piece transfer seal for coupling a nozzle tip to a nozzle of an injection molding apparatus includes a retaining member removably connected to a downstream end of the nozzle and a removably connected nozzle sealing member. The retaining member is comprised of a first material and at least the sealing face of the sealing member is comprised of a second material. In certain applications, the nozzle sealing member is a mold gate insert. In certain applications, the two-piece transfer seal does not retain the nozzle tip, which is metallurgically bonded to the nozzle.

Abstract: An anti-drool mechanism suitable for use in an injection molding system is provided herein. An injection molding machine includes a retractable machine nozzle for injecting a melt stream into a manifold. Between the machine nozzle and the manifold is an anti-drool mechanism, which includes a melt passage and a fixed pin disposed within the melt passage. The fixed pin is sized so that the melt stream will flow around the pin. The fixed pin has a head portion configured to engage with the machine nozzle and includes a first sealing surface. An actuated shut-off collar is also disposed within the melt passage, surrounding the pin, and includes a second sealing surface configured to cut off the flow of the melt stream when in contact with the first sealing surface.

Abstract: The present invention is an injection molding apparatus having a cast manifold. The manifold is made from a cast block and includes at least one pipe and a junction component fixed therein. The junction component has an axial bore having a first end and a second end, and at least one radial bore fluidly connected to the axial bore and having an opening to an outer surface of the junction component. A melt is introduced into the manifold and travels through the radial and axial bores of the junction component and through at least one pipe connected thereto to an injection molding nozzle for injection into a mold cavity. A manifold of the present invention may have a plurality of pipes and junction components to form a branched multi-level cast manifold.