Abstract: Disclosed is a method of manufacturing a manifold for use in plastic injection molding, the method comprising additive manufacturing a melt distribution structure onto a manifold base plate, wherein the manifold base plate comprises a critical assembly feature.

Abstract: A hot-runner system for use with an injection molding system, the hot-runner system including a hot-runner component, a material; and carbon nanotubes being combined with the material. The carbon nanotubes are dispersed, at least in part, in the material and the material includes a metal alloy. The carbon nanotubes are dispersed in the metal alloy, so that the metal alloy and the carbon nanotubes are combined to form a CNT-metal composite material.

Abstract: A hot-runner system for use with an injection molding system, the hot-runner system including a hot-runner component, a material; and carbon nanotubes being combined with the material. The carbon nanotubes are dispersed, at least in part, in the material and the material includes a metal alloy. The carbon nanotubes are dispersed in the metal alloy, so that the metal alloy and the carbon nanotubes are combined to form a CNT-metal composite material.

Abstract: Disclosed is a hot-runner system of an injection molding system, the hot-runner system comprising a hot-runner component, including: a material, and a nano-structured material being combined with the material.

Abstract: Disclosed, amongst other things, is a melt distribution apparatus of a hot runner and a related method for balancing melt flow to a plurality of drops. The melt distribution apparatus includes a plurality of chokes with each choke of the plurality of chokes being associated with a corresponding one of a drop of a plurality of drops. Each choke of the plurality of chokes being configured to contribute, during an injection of a molding material therethrough, a choke melt-pressure loss such that the plurality of chokes contribute an aggregate choke melt-pressure loss that is generally between 10% and 75% of an aggregate hot runner melt-pressure loss.

Abstract: A valve gate piston assembly, in an injection molding system, is positioned in a staggered arrangement such that one piston assembly overlaps that of another valve gate piston assembly thereby minimizing an overall centerline pitch between said piston assemblies. Such a superposed layout of piston assemblies enables larger diameter pistons to occupy a smaller footprint than would be realized should the same piston assemblies be positioned side by side. The use of relatively larger diameter pistons results in an increased force available, for the same input air pressure, to actuate the pistons and valve stems attached thereto, resulting in a higher valve stem closing force. A staggered piston assembly layout also allows independent air circuits to control each piston separately. A combination of multiple piston assemblies may be configured in such a staggered, overlapping array.

Abstract: A hot runner system having a melt distribution system that is reusable and reconfigurable to vary drop or nozzle locations to meet various design requirements. The melt distribution system includes a melt distributor in fluid communication with a melt source, at least one melt conduit in fluid communication with the melt distributor, and at least one nozzle in fluid communication with the at least one melt conduit. The hot runner system also includes a backing plate; a manifold plate detachably connected to the backing plate; a melt distribution system positioned between the backing plate and the manifold plate and having at least one nozzle associated therewith. The hot runner system may be configured and reconfigured to accommodate various drop or nozzle locations.

Abstract: A flexible plate system for a hot runner assembly includes a backing plate; a manifold plate detachably connected to the backing plate; a manifold positioned between the backing plate and the manifold plate and having at least one nozzle associated therewith; and wherein the manifold plate has at least one plate slot that allows the nozzle to extend through the manifold plate and having at least a first lateral dimension substantially larger than the outside diameter of the nozzle. The manifold plate and the backing plate may be configured to have at least one manifold plate cavity and at least one backing plate cavity to accept at least one nozzle insert and at least one piston cylinder insert respectively, the nozzle insert having a nozzle bore or a plurality of insert slots therethrough for installation of the nozzle, and the piston cylinder insert having a cylinder bore for a piston cylinder.

Abstract: Disclosed, amongst other things, is a melt distribution apparatus of a hot runner and a related method for balancing melt flow to a plurality of drops. The melt distribution apparatus includes a plurality of chokes with each choke of the plurality of chokes being associated with a corresponding one of a drop of a plurality of drops. Each choke of the plurality of chokes being configured to contribute, during an injection of a molding material therethrough, a choke melt-pressure loss such that the plurality of chokes contribute an aggregate choke melt-pressure loss that is generally between 10% and 75% of an aggregate hot runner melt-pressure loss.

Abstract: A hot runner system having a melt distribution system that is reusable and reconfigurable to vary drop or nozzle locations to meet various design requirements. The melt distribution system includes a melt distributor in fluid communication with a melt source, at least one melt conduit in fluid communication with the melt distributor, and at least one nozzle in fluid communication with the at least one melt conduit. The hot runner system also includes a backing plate; a manifold plate detachably connected to the backing plate; a melt distribution system positioned between the backing plate and the manifold plate and having at least one nozzle associated therewith. The hot runner system may be configured and reconfigured to accommodate various drop or nozzle locations.

Abstract: A flexible plate system for a hot runner assembly includes a backing plate; a manifold plate detachably connected to the backing plate; a manifold positioned between the backing plate and the manifold plate and having at least one nozzle associated therewith; and wherein the manifold plate has at least one plate slot that allows the nozzle to extend through the manifold plate and having at least a first lateral dimension substantially larger than the outside diameter of the nozzle. The manifold plate and the backing plate may be configured to have at least one manifold plate cavity and at least one backing plate cavity to accept at least one nozzle insert and at least one piston cylinder insert respectively, the nozzle insert having a nozzle bore or a plurality of insert slots therethrough for installation of the nozzle, and the piston cylinder insert having a cylinder bore for a piston cylinder.

Abstract: A valve gate piston assembly, in an injection molding system, is positioned in a staggered arrangement such that one piston assembly overlaps that of another valve gate piston assembly thereby minimizing an overall centerline pitch between said piston assemblies. Such a superposed layout of piston assemblies enables larger diameter pistons to occupy a smaller footprint than would be realized should the same piston assemblies be positioned side by side. The use of relatively larger diameter pistons results in an increased force available, for the same input air pressure, to actuate the pistons and valve stems attached thereto, resulting in a higher valve stem closing force. A staggered piston assembly layout also allows independent air circuits to control each piston separately. A combination of multiple piston assemblies may be configured in such a staggered, overlapping array.

Abstract: An injection molding apparatus that includes a hot runner and a mold. The hot runner includes at least one nozzle that engages a nozzle-receiving cavity of the mold. The molding apparatus further includes a nozzle sleeve surrounding a portion of the nozzle and having a nozzle-sealing opening that receives the nozzle. The nozzle sleeve is movably secured to the hot runner or the mold so that when the mold is removed from the hot runner, the nozzle sleeve remains secured to the corresponding part of the apparatus. When the mold and hot runner are engaged with one another, the nozzle sleeve is springingly urged into sealing engagement with a sealing surface of the nozzle receiving cavity of the mold.

Abstract: A collar for reducing or eliminating leakage between components that moves with respect to each other in the field of injection molding. The collar has an outer portion for receiving an inner portion. The outer portion has a tapered, partial spherical, concave, or convex surface on its inside diameter, and the inner portion has a tapered or partial spherical, convex, or concave surface on its outside diameter. In the preferred embodiment, the inner portion of the collar is operatively assembled into a cavity of the outer portion of the collar, such that the tapered surface of the inner portion is slidably mounted to the tapered surface of the outer portion. The collar is operatively mounted around the outside diameter or circumference of, preferably, a cylindrical device and between two components that move with respect to each other.

Abstract: An injection molding apparatus that includes a hot runner and a mold. The hot runner includes at least one nozzle that engages a nozzle-receiving cavity of the mold. The molding apparatus further includes a nozzle sleeve surrounding a portion of the nozzle and having a nozzle-sealing opening that receives the nozzle. The nozzle sleeve is movably secured to the hot runner or the mold so that when the mold is removed from the hot runner, the nozzle sleeve remains secured to the corresponding part of the apparatus. When the mold and hot runner are engaged with one another, the nozzle sleeve is springingly urged into sealing engagement with a sealing surface of the nozzle receiving cavity of the mold.

Abstract: An external sprue bar position alignment device is comprised of a mounting bracket and a sprue bar alignment frame that is attached to the mounting bracket. The sprue bar alignment frame and mounting bracket define a channel configured to receive a sprue bar upon a mold closing. The sprue bar alignment frame and the mounting bracket are disposed to maintain alignment of an end of the sprue bar with an injection nozzle. The device includes an adjustment device, said adjustment device provided for movement of at least one of the mounting bracket or the sprue bar position alignment frame relative to a path of the sprue bar such that at least one of the mounting block or the sprue bar position alignment frame may bias the sprue bar in a selected direction upon the molding closing. The sprue bar position alignment device may be adjusted without disassembling the mold.

Abstract: An external sprue bar position alignment device is comprised of a mounting bracket and a sprue bar alignment frame that is attached to the mounting bracket. The sprue bar alignment frame and mounting bracket define a channel configured to receive a sprue bar upon a mold closing. The sprue bar alignment frame and the mounting bracket are disposed to maintain alignment of an end of the sprue bar with an injection nozzle. The device includes an adjustment device, said adjustment device provided for movement of at least one of the mounting bracket or the sprue bar position alignment frame relative to a path of the sprue bar such that at least one of the mounting block or the sprue bar position alignment frame may bias the sprue bar in a selected direction upon the molding closing. The sprue bar position alignment device may be adjusted without disassembling the mold.

Abstract: An injection molding apparatus that includes a hot runner and a mold. The hot runner includes at least one nozzle that engages a nozzle-receiving cavity of the mold. The molding apparatus further includes a nozzle sleeve surrounding a portion of the nozzle and having a nozzle-sealing opening that receives the nozzle. The nozzle sleeve is movably secured to the hot runner or the mold so that when the mold is removed from the hot runner, the nozzle sleeve remains secured to the corresponding part of the apparatus. When the mold and hot runner are engaged with one another, the nozzle sleeve is springingly urged into sealing engagement with a sealing surface of the nozzle receiving cavity of the mold.

Abstract: An injection molding apparatus that includes a hot runner and a mold. The hot runner includes at least one nozzle that engages a nozzle-receiving cavity of the mold. The molding apparatus further includes a nozzle sleeve surrounding a portion of the nozzle and having a nozzle-sealing opening that receives the nozzle. The nozzle sleeve is movably secured to the hot runner or the mold so that when the mold is removed from the hot runner, the nozzle sleeve remains secured to the corresponding part of the apparatus. When the mold and hot runner are engaged with one another, the nozzle sleeve is springingly urged into sealing engagement with a sealing surface of the nozzle receiving cavity of the mold.

Abstract: A collar for reducing or eliminating leakage between components, which move with respect to each other in the field of injection molding. The collar has an outer portion for receiving an inner portion. The outer portion has a tapered or partial spherical surface on its inside diameter, and the inner portion has a tapered or partial spherical surface on its outside diameter. In the preferred embodiment, the inner portion of the collar is operatively assembled into a cavity of the outer portion of the collar, such that the tapered surface of the inner portion is slidably mounted to the tapered surface of the outer portion. The collar is operatively mounted around the outside diameter or circumference of a cylindrical device and between two components that move with respect to each other. Springs, discs, cylinders or other device are used to create an axial force AF between the components, which move with respect to each other.