Abstract: An improved heater band for a hot runner injection molding machine. The heater band includes a cylindrical sleeve adapted to be disposed about a nozzle body in combination with a first wire heating element and a second wire heating element. The first wire heating element includes two contact terminals and an intermediate portion therebetween. The intermediate portion of the first wire heating element is disposed within the cylindrical sleeve. The second wire heating element includes two contact terminals and an intermediate portion therebetween. The intermediate portion of the second wire heating element is also disposed within the cylindrical sleeve. The intermediate portions of the heating elements are adjacent to and axially offset from one another within the cylindrical sleeve. The first wire heating element and the second wire heating element can be alternatively connected to an electrical power supply to extend the operational life of the heater band.

Abstract: An improved hot runner system is provided. The hot runner system includes a hot drop having an inlet for receiving molten material, the inlet diverging into first and second channels that converge at a feeder tube for providing an even distribution of molten material in a mold cavity. The hot runner system further includes a valve pin adapted to reciprocate within the feeder tube for opening and closing the valve gate, the valve pin being moveable in response to activation of first and second linear actuators disposed exterior to the hot drop. The linear actuators are moveable in unison with each other and are joined to the valve pin via a cross-bar that extends through an interior portion of the hot drop between the first and second channels.

Abstract: An improved hot runner system is provided. The hot runner system includes a hot drop having an inlet for receiving molten material, the inlet diverging into first and second channels that converge at a feeder tube for providing an even distribution of molten material in a mold cavity. The hot runner system further includes a valve pin adapted to reciprocate within the feeder tube for opening and closing the valve gate, the valve pin being moveable in response to activation of first and second linear actuators disposed exterior to the hot drop. The linear actuators are moveable in unison with each other and are joined to the valve pin via a cross-bar that extends through an interior portion of the hot drop between the first and second channels.

Abstract: An improved heater band for a hot runner injection molding machine. The heater band includes a cylindrical sleeve adapted to be disposed about a nozzle body in combination with a first wire heating element and a second wire heating element. The first wire heating element includes two contact terminals and an intermediate portion therebetween. The intermediate portion of the first wire heating element is disposed within the cylindrical sleeve. The second wire heating element includes two contact terminals and an intermediate portion therebetween. The intermediate portion of the second wire heating element is also disposed within the cylindrical sleeve. The intermediate portions of the heating elements are adjacent to and axially offset from one another within the cylindrical sleeve. The first wire heating element and the second wire heating element can be alternatively connected to an electrical power supply to extend the operational life of the heater band.

Abstract: An improved actuator for a valve gate assembly is provided. The actuator includes a planetary assembly for converting rotation of an electrical motor into linear movement of a valve gate pin while also providing mechanical advantage to the motor against injection pressures from 15,000 psi to at least 25,000 psi. An internal cooling volume surrounds the motor for continuously cooling the motor with water, and an internal encoder converts an angular rotation within the actuator into an analog or digital signal for output to a controller.

Abstract: A pressure resistant drop tip nozzle assembly for an injection molding machine having a nozzle body with a nozzle passage extending axially through said nozzle body between a nozzle inlet and a nozzle outlet. The assembly includes a drop tip which has a body connected to the nozzle outlet of said nozzle body. The drop tip has a drop tip bore extending between a drop inlet located adjacent said nozzle outlet body and a drop outlet. A tapered drop passage located at said drop outlet defines a resin flow aperture where resin leaves said drop tip. An internal heating insert is positioned within said drop tip bore. The drop tip body is connected to the nozzle body via a mechanical connection such as screw threads. A reinforcing weld preferably via a continuous laser weld is provided between said drop tip body and said nozzle body.

Abstract: A pressure resistant drop tip nozzle assembly for an injection molding machine having a nozzle body with a nozzle passage extending axially through said nozzle body between a nozzle inlet and a nozzle outlet. The assembly includes a drop tip which has a body connected to the nozzle outlet of said nozzle body. The drop tip has a drop tip bore extending between a drop inlet located adjacent said nozzle outlet body and a drop outlet. A tapered drop passage located at said drop outlet defines a resin flow aperture where resin leaves said drop tip. An internal heating insert is positioned within said drop tip bore. The drop tip body is connected to the nozzle body via a mechanical connection such as screw threads. A reinforcing weld preferably via a continuous laser weld is provided between said drop tip body and said nozzle body.

Abstract: A pressure resistant drop tip nozzle assembly for an injection molding machine having a nozzle body with a nozzle passage extending axially through said nozzle body between a nozzle inlet and a nozzle outlet. The assembly includes a drop tip which has a body connected to the nozzle outlet of said nozzle body. The drop tip has a drop tip bore extending between a drop inlet located adjacent said nozzle outlet body and a drop outlet. A tapered drop passage located at said drop outlet defines a resin flow aperture where resin leaves said drop tip. An internal heating insert is positioned within said drop tip bore. The drop tip body is connected to the nozzle body via a mechanical connection such as screw threads. A reinforcing weld preferably via a continuous laser weld is provided between said drop tip body and said nozzle body.

Abstract: A valve gate assembly for regulating a flow of molten material into a mold. The valve gate assembly includes a movable valve that can be positioned between a fully closed position and a fully open position. The valve gate assembly further includes an actuating system operatively cooperating with the valve to move the valve and infinitely position the valve between the fully closed position and the fully open position.

Abstract: A valve gate assembly for regulating a flow of molten material into a mold. The valve gate assembly includes a movable valve that can be positioned between a fully closed position and a fully open position. The valve gate assembly further includes an actuating system operatively cooperating with the valve to move the valve and infinitely position the valve between the fully closed position and the fully open position.

Abstract: A valve gate assembly for regulating a flow of molten material into a mold. The valve gate assembly includes a movable valve that can be positioned between a fully closed position and a fully open position. The valve gate assembly further includes an actuating system operatively cooperating with the valve to move the valve and infinitely position the valve between the fully closed position and the fully open position.

Abstract: A valve gate assembly for regulating a flow of molten material into a mold. The valve gate assembly includes a movable valve that can be positioned between a fully closed position and a fully open position. The valve gate assembly further includes an actuating system operatively cooperating with the valve to move the valve and infinitely position the valve between the fully closed position and the fully open position.

Abstract: A valve gate assembly for regulating a flow of molten material into a mold. The valve gate assembly includes a movable valve that can be positioned between a fully closed position and a fully open position. The valve gate assembly further includes an actuating system operatively cooperating with the valve to move the valve and infinitely position the valve between the fully closed position and the fully open position.

Abstract: A drop tip is provided for conveying injection molding material from a molding material supply into a mold. The drop tip has a body including an internal bore and a drop passage extending from the internal bore. The internal bore has an arcuate lower end terminating in a gate to prevent retention of molten material therein.

Abstract: A manifold for conveying injection molding material into a mold from a molding material supply and method for making same includes a main flow member having a central flow passage extending through the main flow member along a longitudinal axis of the main flow member. The main flow member also includes a plurality of branching passages each transverse to and in fluid communication with the central flow passage. The main flow member has an outer surface that is generally round in cross sectional shape. The outer surface is machined so as to be generally round in cross sectional shape.

Abstract: An injection molding system for injection molding a plurality of molten materials into a mold cavity includes a nozzle, a drop tip supported by the nozzle, and a central bore extending through the nozzle and drop tip. The injection molding system also includes a first and second flow passage each extending through the nozzle, so as to define a first and second nozzle flow passage, and drop tip, so as to define a first and second drop tip flow passage. The first and second drop tip flow passages each include a plurality of branching portions each defining a junction at which the respective flow passage communicates fluidly with the central bore.

Abstract: A valve gate assembly for regulating a flow of molten material into a mold. The valve gate assembly includes a movable valve that can be positioned between a fully closed position and a fully open position. The valve gate assembly further includes an actuating system operatively cooperating with the valve to move the valve and infinitely position the valve between the fully closed position and the fully open position.

Abstract: A valve gate assembly for regulating a flow of molten material into a mold. The valve gate assembly includes a movable valve that can move between a fully closed position and a fully open position. The valve gate assembly further includes an actuating system operatively cooperating with the valve to move the valve and infinitely position the valve between the fully closed position and the fully open position.

Abstract: A valve gate assembly is provided for regulating a flow of molten material through a gate and into a mold. The valve gate assembly includes a movable valve having a closed position closing the gate to prevent molten material from entering the mold and an opened position opening the gate to allow molten material to enter the mold. The valve gate assembly further includes a biasing assembly operatively cooperating with the valve and providing a force to urge the valve in the closed position. The valve has a shoulder for cooperating with the molten material to create backpressure to move the valve against the force to the open position.

Abstract: A manifold assembly is provided for conveying injection molding material from a molding material supply into a mold. The manifold assembly includes a manifold having a manifold flow passage extending therealong. The manifold assembly also includes at least one nozzle extending outwardly from the manifold to a distal end. The at least one nozzle includes a central nozzle passage extending from and in fluid communication with the manifold flow passage. The at least one nozzle extends on an angle from the manifold to be tangential to an arcuate surface of a part to be molded.