US20030008034A1 - Method and apparatus for injection molding articles - Google Patents

Method and apparatus for injection molding articles Download PDF

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Publication number
US20030008034A1
US20030008034A1 US09/900,083 US90008301A US2003008034A1 US 20030008034 A1 US20030008034 A1 US 20030008034A1 US 90008301 A US90008301 A US 90008301A US 2003008034 A1 US2003008034 A1 US 2003008034A1
Authority
US
United States
Prior art keywords
nozzle
accordance
valve member
cavity
communication
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US09/900,083
Other languages
English (en)
Inventor
Joachim Niewels
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Husky Injection Molding Systems Ltd
Original Assignee
Husky Injection Molding Systems Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Husky Injection Molding Systems Ltd filed Critical Husky Injection Molding Systems Ltd
Priority to US09/900,083 priority Critical patent/US20030008034A1/en
Assigned to HUSKY INJECTION MOLDING SYSTEMS, LTD. reassignment HUSKY INJECTION MOLDING SYSTEMS, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NIEWELS, JOACHIM JOHANNES
Assigned to HUSKY INJECTION MOLDING SYSTEMS INC. reassignment HUSKY INJECTION MOLDING SYSTEMS INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HUSKY INJECTION MOLDING SYSTEMS LTD., A CANADIAN CORPORATION
Priority to CNB2005100737502A priority patent/CN100398295C/zh
Priority to EP02729720A priority patent/EP1406754B1/en
Priority to ES02729720T priority patent/ES2291468T3/es
Priority to DE60221845T priority patent/DE60221845T2/de
Priority to JP2003510234A priority patent/JP2004520984A/ja
Priority to PCT/CA2002/000774 priority patent/WO2003004243A1/en
Priority to AT02729720T priority patent/ATE369964T1/de
Priority to CA002449179A priority patent/CA2449179A1/en
Priority to CNA028136454A priority patent/CN1537045A/zh
Priority to TW091111704A priority patent/TW590870B/zh
Publication of US20030008034A1 publication Critical patent/US20030008034A1/en
Priority to US10/670,870 priority patent/US7037103B2/en
Priority to US10/847,854 priority patent/US7156651B2/en
Priority to PCT/CA2005/000622 priority patent/WO2005110701A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/2701—Details not specific to hot or cold runner channels
    • B29C45/2708—Gates
    • B29C45/2711—Gate inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/278—Nozzle tips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/28—Closure devices therefor
    • B29C45/2806—Closure devices therefor consisting of needle valve systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/28—Closure devices therefor
    • B29C45/2806—Closure devices therefor consisting of needle valve systems
    • B29C2045/2879—Back flow of material into nozzle channel

Definitions

  • This invention relates to injection molding systems. More specifically, the present invention relates to a valve gating system found in injection molding systems.
  • Injection molding nozzles are well known and are used to inject materials, such as plastic, into the cavity of a mold.
  • such nozzles receive molten material, such as plastic, from an injection molding machine and direct the same into a mold cavity through a passage called a gate.
  • molten material such as plastic
  • the transfer of molten material through the gate must be stopped.
  • thermal, or open, gating; and valve gating two methods exist for stopping the transfer of molten material through the gate.
  • the gate In thermal gating, the gate is an open aperture through which molten material passes during an injection operation.
  • the gate is rapidly cooled at the end of the injection portion of the cycle, when the injection pressure is removed, to “freeze” the injected material into a plug.
  • This plug remains in the gate to prevent drool of molten material from the gate when the mold is open for the ejection of the molded part.
  • the cooling applied to the gate is removed and hot molten material from the injection molding machine pushes the plug into the mold cavity, where it melts and mixes with the newly provided molten material.
  • valve gating In valve gating, the opening and closing of the gate is independent of injection pressure and/or cooling and is achieved mechanically with a valve stem. This stem can be moved between an open position, wherein flow of molten materials through the gate is permitted, and a closed position wherein the gate is closed by entry of the valve stem into the gate which establishes a seal, preventing molten materials from passing through the gate.
  • Valve gating is well known and examples of such systems are shown in U.S. Pat. Nos. 2,878,515; 3,023,458; and 3,530,539, each being incorporated herein by reference.
  • valve gating is preferable to thermal gating because it can reduce the undesired gate vestige which results on the finished molded part.
  • problems with valve gating systems there are problems with valve gating systems.
  • valve stem and gate each have a complementary sealing portion which are brought into contact to seal the gate.
  • a complementary sealing portion typically there is a 0.001′′-0.002′′ diametrical clearance between the valve stem and the gate sealing portion.
  • a slight misalignment of the stem with the gate will cause the stem to strike the gate sealing portion. Over time, this will cause the gate area to wear and become misshapen. Now that the gate sealing area is worn, the stem no longer stops the flow of molten material and a small amount of molten material will migrate between the stem and the worn gate sealing area.
  • the mold halves will open and the molded article in a somewhat solidified state will be removed from the area of the stem/gate area. Due to the entrapped molten material between the worn gate area and the stem, the molded article will not break away cleanly when the mold is opened, but rather will tear away from the gate area, which results in a blemished vestige on the molded article.
  • a nozzle assembly 10 is comprised of an elongated nozzle bushing 12 with a nozzle tip 16 affixed co-axially therein.
  • an insulator 14 is affixed to a proximal end of the nozzle tip 16 thereby thermally insulating the heated nozzle assembly 10 from the cooled cavity plate 34 .
  • a movable valve member 18 extends co-axially in the nozzle assembly 10 and is selectably positioned in or out of a passageway/gate area 22 .
  • a melt channel 20 surrounds the valve member 18 and runs the length of the nozzle assembly 10 to communicate a flowable material to a mold cavity 28 .
  • valve member 18 When the valve member 18 is placed in a fully closed position (as shown in FIG. 1), a sealing portion 25 in the cavity plate 34 sealingly surrounds the valve member 18 to shut off the flow of material to the mold cavity 28 . As shown in FIG. 1, a face portion 21 of valve member 18 defines the entire top of the vestige 26 of the molded article. A chamfer 36 is typically provided along the face of the valve member 18 to help guide the valve member into the gate area and reduce wear of the valve member and cavity plate 34 .
  • valve member 18 Due to the close fit of the valve member 18 to the sealing portion 25 , any misalignment that exists between their respective interfaces will cause the valve member 18 to strike the surface of the sealing portion 25 which will ultimately lead to a deterioration of the seal portion 25 and/or the valve member 18 .
  • valve member 18 At the end of the injection cycle, the valve member 18 is moved into its closed position as previously described and the mold cavity is held in a closed position with a core 30 for a predetermined cycle time to allow the molten material to cool and solidify, thereby forming the molded article. Once the molded article has been allowed to cool to a sufficient level, the core 30 with the molded article thereon is moved in the direction as denoted by arrow A, and the vestige 26 is pulled away from the face portion 21 of the valve member 18 .
  • valve member 18 If enough wear exists between the valve member 18 and the sealing portion 25 , a small amount of molten material will migrate therein, and as the mold core 30 and the molded article 27 are moved to an open position, a peeled edge 38 will form on the vestige 26 of the molded article 27 .
  • valve member 18 As the valve member 18 is in the flow of molten material when the gate is open, it can become quite hot. When the gate is closed by the valve member 18 , the hot tip of the valve member 18 can be difficult to cool as the mold cavity 28 is cooled and this can result in a need for increased cycle times to permit the necessary cooling, and/or can result in undesirable characteristics in the molded article 27 . Specifically, as the material in the mold cavity 28 adjacent the valve member 18 is cooled less efficiently due to the hot tip, parts molded from thermally sensitive materials such as PET can suffer from an enlarged area of crystallinity 40 or other undesired characteristics. In addition, since the entire top surface of the vestige 26 is in contact with the face portion 21 of the hot valve member 18 , the molten material adjacent the face portion 21 remains somewhat molten and stringing and an uneven edge forms when the mold is opened.
  • the primary objective of the present invention is to provide an improved injection molding system with a valve gating system that reduces or obviates the drawbacks of the prior art.
  • Another object of the present invention is to provide an insert that interfaces with a valve member in an injection molding system that reduces or eliminates the formation of peeled edges along a vestige of a molded article.
  • Yet another object of the present invention is to provide a gate insert in the mold plate adjacent the valve member that may be easily replaced.
  • a mold cavity with a vestige cross-sectional area that is larger than the cross-sectional area of the valve member so that the periphery of the vestige is cooled quicker than the interior portion of the vestige.
  • a replaceable insert is provided to help guide the valve member into a sealing position with the gate. Replacement of this insert can easily be performed whenever the wear of the insert reaches a predetermined and unacceptable level.
  • FIG. 1 is a simplified cross-sectional view of an injection molding nozzle in accordance with the prior art
  • FIG. 2 is a partial cross-sectional view of a molded article in accordance with the prior art
  • FIGS. 3 and 3 a are simplified cross-sectional views of exemplicative embodiments in accordance with the present invention.
  • FIGS. 4 a and 4 b are partial cross-sectional views of alternate exemplicative embodiments in accordance with the present invention.
  • FIG. 5 is a simplified partial cross-sectional view of a molded article.
  • an injection molding nozzle assembly 10 in accordance with the present invention is located in a cavity plate 34 for the communication of a flowable material to a mold cavity 28 for the formation of a molded article therein.
  • Cavity plate 34 is provided with a plurality of cooling passageways 32 therein for the communication of a cooling fluid for the removal of heat from the cavity plate to cool and solidify the flowable material in the mold cavity 28 .
  • the nozzle assembly 10 is comprised of an elongated nozzle bushing 12 with a nozzle tip 16 affixed to a proximal end of the nozzle bushing.
  • the nozzle tip 16 is threaded to the nozzle bushing 12 , but any such suitable means could be used.
  • a heater 17 is wrapped around the nozzle assembly 10 to maintain the flowable material in a viscous state.
  • an optional insulator 14 is located between the nozzle tip 16 and the cooled cavity plate 34 to reduce the transfer of heat from the hot nozzle tip 16 to the cooled cavity plate 34 .
  • valve member 18 Located co-axially in the nozzle assembly 10 is a movable valve member 18 that extends adjacent a vestige 26 of the mold cavity 28 .
  • the valve member 18 is a slender elongated cylindrical piece that is moved up and down to an open and closed position respectively.
  • the valve member 18 When the valve member 18 is in the open position as shown by phantom line 50 , the flowable material in melt channel 20 is allowed to enter the mold cavity 28 .
  • the valve member 18 When placed in the closed position, as shown in FIG. 1, the valve member 18 is in sealing communication with a sealing portion 25 thereby stopping the flow of material to the mold cavity 28 .
  • an insert 42 with a passageway 41 formed therein is placed in a cavity 44 located in the cavity plate 34 in alignment with the valve member 18 .
  • the sealing portion 25 is located in this replaceable insert 42 to allow for easy maintenance when leakage around the valve member 18 starts to occur.
  • the insert 42 may optionally provide a first chamfer 46 to help guide the valve member 18 when it first enters the passageway 41 and a second chamfer 48 to help guide the valve member further into the sealing portion 25 . These chamfers act to reduce wear on both the valve member 18 and the insert 42 and prolong the useable life of both components.
  • Vestige 26 has a cross-sectional area larger than the face portion 21 of the valve member 18 . As such, a portion 23 of the vestige 26 is in thermal communication with the insert 42 . Given that the insert 42 is placed in the cooled cavity plate 34 , the insert 42 will cool portion 23 faster than the portion in contact with face portion 21 of the hot valve member 18 . This differential cooling action will allow portion 23 to solidify before the area adjacent face portion 21 . When core 30 is retracted to remove the molded article from the mold cavity 28 , this now solidified portion 23 will tend to breakaway more cleanly than the prior art.
  • any tearing that may occur when the mold is opened is reduced or eliminated because the tear is not on the surface of the vestige/preform as in the prior art.
  • this clean break will result in a more uniform and flat vestige 26 than previously seen.
  • a reduced area of crystallinity 40 will form inside the molded article 27 due to the improved cooling of the vestige 26 .
  • FIG. 3A an alternative embodiment in accordance with the present invention is shown which is identical to the embodiment in FIG. 3 except for the removal of the insert 42 .
  • the sealing portion 25 is now located in the cavity plate 34 . Cooling of portion 23 will still occur quicker than in the remainder of the vestige 26 , which will allow for a substantially clean break when mold core 30 is retracted.
  • FIGS. 4 a and 4 b show alternative embodiments of the insert 42 and the valve member 18 .
  • the valve member 18 has a chamfer 54 near the vestige 26 .
  • a reduced diameter section of the valve member is in sealing communication with the sealing portion 25 when in the closed position.
  • At least one elongated recess 56 is formed in the surface of the valve member 18 which allows the flowable material to be forced up along the valve member 18 as the valve member is brought to the closed position.
  • Chamfers 46 and 48 help guide the valve member 18 as it enters the passageway 41 and seats in the sealing portion 25 .
  • FIG. 4 b shows the valve member 18 as one continuous cylinder down to the chamfer at the very bottom.
  • the passageway 41 in the insert 42 is also a uniform diameter for most of its length, except for the lead in chamfer 46 .
  • the sealing portion 25 can be longer and provide a longer lasting seal.
  • the recess 56 allows the flowable material to flow up out of passageway 41 as the valve member 18 is brought to a closed position.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
US09/900,083 2001-07-06 2001-07-06 Method and apparatus for injection molding articles Abandoned US20030008034A1 (en)

Priority Applications (14)

Application Number Priority Date Filing Date Title
US09/900,083 US20030008034A1 (en) 2001-07-06 2001-07-06 Method and apparatus for injection molding articles
CNA028136454A CN1537045A (zh) 2001-07-06 2002-05-27 用于注射成型制品的方法和设备
EP02729720A EP1406754B1 (en) 2001-07-06 2002-05-27 Apparatus for injection molding articles
JP2003510234A JP2004520984A (ja) 2001-07-06 2002-05-27 物品を射出成形するための方法および装置
CA002449179A CA2449179A1 (en) 2001-07-06 2002-05-27 Method and apparatus for injection molding articles
ES02729720T ES2291468T3 (es) 2001-07-06 2002-05-27 Aparato para el moldeo por inyeccion de articulos.
DE60221845T DE60221845T2 (de) 2001-07-06 2002-05-27 Vorrichtung zum spritzgiessen von kunstoffgegenständen
CNB2005100737502A CN100398295C (zh) 2001-07-06 2002-05-27 用于注射成型制品的方法和设备
PCT/CA2002/000774 WO2003004243A1 (en) 2001-07-06 2002-05-27 Method and apparatus for injection molding articles
AT02729720T ATE369964T1 (de) 2001-07-06 2002-05-27 Vorrichtung zum spritzgiessen von kunstoffgegenständen
TW091111704A TW590870B (en) 2001-07-06 2002-05-31 Injection molding apparatus
US10/670,870 US7037103B2 (en) 2001-07-06 2003-09-25 Apparatus for injection molded articles
US10/847,854 US7156651B2 (en) 2001-07-06 2004-05-19 Apparatus for injection molding articles
PCT/CA2005/000622 WO2005110701A1 (en) 2001-07-06 2005-04-25 Improved apparatus for injection molding articles

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US09/900,083 US20030008034A1 (en) 2001-07-06 2001-07-06 Method and apparatus for injection molding articles

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US10/670,870 Continuation-In-Part US7037103B2 (en) 2001-07-06 2003-09-25 Apparatus for injection molded articles

Publications (1)

Publication Number Publication Date
US20030008034A1 true US20030008034A1 (en) 2003-01-09

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Family Applications (2)

Application Number Title Priority Date Filing Date
US09/900,083 Abandoned US20030008034A1 (en) 2001-07-06 2001-07-06 Method and apparatus for injection molding articles
US10/670,870 Expired - Fee Related US7037103B2 (en) 2001-07-06 2003-09-25 Apparatus for injection molded articles

Family Applications After (1)

Application Number Title Priority Date Filing Date
US10/670,870 Expired - Fee Related US7037103B2 (en) 2001-07-06 2003-09-25 Apparatus for injection molded articles

Country Status (10)

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US (2) US20030008034A1 (enrdf_load_stackoverflow)
EP (1) EP1406754B1 (enrdf_load_stackoverflow)
JP (1) JP2004520984A (enrdf_load_stackoverflow)
CN (2) CN1537045A (enrdf_load_stackoverflow)
AT (1) ATE369964T1 (enrdf_load_stackoverflow)
CA (1) CA2449179A1 (enrdf_load_stackoverflow)
DE (1) DE60221845T2 (enrdf_load_stackoverflow)
ES (1) ES2291468T3 (enrdf_load_stackoverflow)
TW (1) TW590870B (enrdf_load_stackoverflow)
WO (1) WO2003004243A1 (enrdf_load_stackoverflow)

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US20040137107A1 (en) * 2002-11-21 2004-07-15 Denis Babin Hot runner nozzle with a tip, a tip surrounding piece and an alignment piece
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US20050003039A1 (en) * 2001-10-03 2005-01-06 Denis Babin Nozzle seal for an injection molding apparatus
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CN102802909A (zh) * 2010-04-05 2012-11-28 赫斯基注塑系统有限公司 含有相对于阀针尖端定位的树脂止流装置的模具工具组件
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DE60221845D1 (de) 2007-09-27
DE60221845T2 (de) 2008-05-08
ATE369964T1 (de) 2007-09-15
WO2003004243A1 (en) 2003-01-16
TW590870B (en) 2004-06-11
US20040058031A1 (en) 2004-03-25
US7037103B2 (en) 2006-05-02
EP1406754A1 (en) 2004-04-14
JP2004520984A (ja) 2004-07-15
CA2449179A1 (en) 2003-01-16
CN100398295C (zh) 2008-07-02
CN1680085A (zh) 2005-10-12
CN1537045A (zh) 2004-10-13
EP1406754B1 (en) 2007-08-15

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