US20190099932A1 - Edge-gated injection molding apparatus - Google Patents
Edge-gated injection molding apparatus Download PDFInfo
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- US20190099932A1 US20190099932A1 US16/152,124 US201816152124A US2019099932A1 US 20190099932 A1 US20190099932 A1 US 20190099932A1 US 201816152124 A US201816152124 A US 201816152124A US 2019099932 A1 US2019099932 A1 US 2019099932A1
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- 238000001746 injection moulding Methods 0.000 title claims abstract description 45
- 230000002457 bidirectional effect Effects 0.000 claims abstract description 112
- 239000000463 material Substances 0.000 claims abstract description 17
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- 238000004891 communication Methods 0.000 claims description 33
- 239000012778 molding material Substances 0.000 description 118
- 230000000712 assembly Effects 0.000 description 21
- 238000000429 assembly Methods 0.000 description 21
- 238000002347 injection Methods 0.000 description 11
- 239000007924 injection Substances 0.000 description 11
- 239000011162 core material Substances 0.000 description 10
- 238000007789 sealing Methods 0.000 description 10
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- 125000006850 spacer group Chemical group 0.000 description 6
- 238000011144 upstream manufacturing Methods 0.000 description 4
- 238000009826 distribution Methods 0.000 description 3
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- 238000004519 manufacturing process Methods 0.000 description 2
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- 230000002829 reductive effect Effects 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
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- 239000000654 additive Substances 0.000 description 1
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Images
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
- B29C45/2735—Sprue channels ; Runner channels or runner nozzles for non-coaxial gates, e.g. for edge gates
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
- B29K2105/258—Tubular
Definitions
- the disclosure relates generally to an injection molding system and, in particular, to an edge-gated injection molding system.
- Edge gating is commonly used in the manufacture of slender elongate molded articles such as pipettes or a syringe barrels.
- the cavity defining the molded article usually has only one gate through which molding material flows in a direction that is generally transverse to the longitudinal axis of the molded article.
- Pressure within the cavity from molding material flowing through the gate on only one side of the part can adversely affect part filling and/or part geometry. For example, when examining the fill rate of such parts, the side of the part on which the gate is located generally fills first, thus creating an angled flow front as the molding material advances away from the gate. Further, if injection pressure is high enough, the mold core, which defines the inside of the molded article, can be deflected away from the gate.
- each mold cavity receives molding material from two injection nozzles and each injection nozzle delivers molding material to two mold cavities. While the problem of core shift is reduced in this configuration, the cavitation density of the mold suffers as a result of unused space at the center or the pitch circle. Furthermore, should the cavity/nozzle groupings be increased to, for example, groupings of eight cavities and eight injection nozzles spaced about pitch circles that are used in the above described configuration the cavitation density of the mold is adversely affected as the unused space at the center of each pitch circle increases greatly with an increase in pitch circle diameter.
- An aspect of the embodiments hereof are directed toward an edge gating injection molding apparatus for delivering a moldable material to an array of mold cavities, the array can have a first column and a last column of mold cavities, the edge gating injection molding apparatus comprising: a unidirectional delivery body for delivering a first stream of the moldable material to a different one of each mold cavity of the first column and the last column of mold cavities, via a first location of the different one of each mold cavity of the first column and the last column of mold cavities; and a bidirectional delivery body for delivering a second stream of the moldable material to the different one of each mold cavity of the first column and the last column of mold cavities, via a second location of the different one of each mold cavity of the first column and the last column of mold cavities.
- each cavity insert can have a pair of opposing mold gates; a unidirectional delivery body in fluid communication with a molding material source, and positioned outside of a first column of the array; another unidirectional delivery body in fluid communication with the molding material source, and positioned outside of the last column of the array; and n ⁇ 1 bidirectional delivery bodies in fluid communication with the molding material source, each of the n ⁇ 1 bidirectional delivery bodies positioned between adjacent columns of the array, wherein each cavity can receive molding material from at least one bidirectional delivery body.
- FIG. 1 is a sectional view of a three cavity edge-gated injection molding apparatus in accordance with an embodiment of the present disclosure.
- FIG. 1A is a schematic of the arrangement of components of FIG. 1 .
- FIG. 2 is a sectional view of a two cavity edge-gated injection molding apparatus in accordance with another embodiment of the present disclosure.
- FIG. 2A is a schematic of the arrangement of components of FIG. 2 .
- FIG. 3 is a sectional view of a two cavity edge-gated injection molding apparatus in accordance with another embodiment of the present disclosure.
- FIG. 3A is a schematic of the arrangement of components of FIG. 3 .
- FIG. 4 is a bottom view of delivery bodies and molded articles molded thereby in accordance with an embodiment of the present disclosure removed from the injection molding system.
- FIG. 4A is a schematic of the arrangement of components of FIG. 4 .
- FIG. 5A is a perspective view of a bidirectional delivery body of FIG. 4 .
- FIG. 5B is sectional view of the bidirectional delivery body of FIG. 5 taken along line B-B thereof.
- FIG. 5C is sectional view of the bidirectional delivery body of FIG. 5 taken along line C-C thereof.
- FIG. 5D is a sectional view of the bidirectional delivery body of FIG. 5 taken along line D-D thereof.
- FIG. 5E is a sectional view of the bidirectional delivery body of FIG. 5 taken along line E-E thereof.
- FIG. 5F is a perspective view of a bidirectional delivery body of FIG. 4 with transfer bodies and tip assemblies.
- FIG. 6 is a perspective view of a plug removed from a bidirectional delivery body of FIG. 4 .
- FIG. 6A is sectional view through the plug of FIG. 6 taken along line A-A thereof.
- FIG. 7 is perspective view of a plug in accordance with another embodiment of the present disclosure removed from a bidirectional delivery body of FIG. 4 .
- FIG. 7A is a bottom view of the plug of FIG. 7 .
- FIG. 8 is a top view of an edge-gated injection molding apparatus in accordance with another embodiment.
- FIG. 8A is a section view of the edge-gated injection molding apparatus of FIG. 8 taken along line A-A.
- FIG. 8B is a perspective view of a portion of the injection molding apparatus of FIG. 8 .
- FIG. 8C is the perspective view of the edge-gated injection molding apparatus of FIG. 8 with the manifold and inlet removed.
- FIG. 8D is a perspective view of a bidirectional delivery body from the edge-gated injection molding apparatus of FIG. 8 .
- downstream is used with reference to the general direction of mold material flow from an injection unit to a mold cavity of an injection molding system and also to the order of components, or features thereof through which the mold material flows, from an inlet of the injection molding system to a mold cavity
- upstream is used with reference to the opposite direction.
- each of the terms “left”, “right”, “top” and “bottom” is used with reference to the non-limiting orientation of components as shown in the figures. While specific configurations and arrangements are discussed, it should be understood that this is done for illustrative purposes only. A person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the scope of the present disclosure.
- FIG. 1 is a section view of a three cavity edge-gated injection molding apparatus in accordance with an embodiment hereof and is generally indicated by reference numeral 100 , features and aspects of which can be used accordingly with the other embodiments.
- FIG. 1A is a schematic of the arrangement of components of FIG. 1 .
- Edge-gated injection molding apparatus includes a back plate 101 , a mold plate 102 , cavity inserts 103 , and a cover plate 104 all held together by a plurality of socket head cap screws 105 or the like.
- Back plate 101 , mold plate 102 , cover plate 104 , and cavity insert 103 may be provided with fluid channels, such as fluid channel 106 called out on mold plate 102 , through which a fluid is circulated to maintain injection molding apparatus 100 at a required processing temperature.
- Cavity insert 103 is located in a bore 107 in mold plate 102 and defines a cavity 108 which defines an outside surface of the article being molded. Cavity 108 together with a mold core (not shown) define the general shape of the article being molded by injection molding apparatus 100 .
- each cavity insert 103 is provided with a pair of gates 109 , (gate 109 A refers to the gate to the left of cavity 108 as viewed on page, gate 109 B refers to the gate to the right of cavity 108 as viewed on page, gates 109 A, 109 B are generically referenced as gate 109 ).
- gate 109 A is at a first location and gate 109 B is at a second location, the first and second locations are substantially diametrically opposite one another relative to an axial center line 110 of cavity 108 .
- gates 109 A, 109 B may be offset relative to each other and/or center line 110 of cavity 108 .
- Edge-gated injection molding apparatus 100 further includes an inlet 112 , a manifold 113 , a plurality of transfer bodies 114 , and a plurality of delivery bodies 115 in the form of unidirectional delivery bodies 115 A and bidirectional delivery bodies 115 B.
- each of inlet 112 , manifold 113 , transfer bodies 114 , and delivery bodies 115 is provided with a heater, such as heater 116 shown on delivery body 115 , in the form of an embedded resistance heater for maintaining each of inlet 112 , manifold 113 , transfer bodies 114 , and delivery bodies 115 at a required processing temperature.
- a heater such as heater 116 shown on delivery body 115 , in the form of an embedded resistance heater for maintaining each of inlet 112 , manifold 113 , transfer bodies 114 , and delivery bodies 115 at a required processing temperature.
- inlet 112 manifold 113 , transfer bodies 114 , and delivery bodies 115 are provided with a heater.
- Inlet 112 , manifold 113 , transfer bodies 114 , and delivery bodies 115 can be referred to generally as a hot runner system.
- a molding machine nozzle (not shown) interfaces with inlet 112 at seat 117 to deliver a stream of moldable material under pressure to a manifold channel 118 of the manifold 113 .
- Manifold 113 is located in a pocket 119 in mold plate 102 , and serves to deliver the molding material stream from the molding machine nozzle (not shown) to each of the plurality of transfer bodies 114 via a respective manifold outlet 120 .
- Pocket 119 is sized in order to maintain an insulating air space 121 around manifold 113 .
- manifold 113 delivers the molding material stream from inlet 112 to four transfer bodies 114 .
- Each transfer body 114 is configured for alignment between a transfer channel 123 and a respective manifold outlet 120 to receive a molding material stream from manifold channel 118 .
- Transfer body 114 has a flange 124 that sits in a corresponding shoulder 125 of a clearance bore 126 in mold plate 102 . Similar to pocket 119 described above, clearance bore 126 creates an insulating air space 127 between transfer body 114 and mold plate 102 .
- a support disk 128 is positioned between manifold 113 and back plate 101 to focus the force from manifold heat expansion directly over each transfer body 114 .
- the flange 124 and mold plate shoulder 125 arrangement, together with support disk 128 supports the load from heat expansion of manifold 113 while still allowing the load from manifold 113 to be used as a sealing means/force between transfer bodies 114 and manifold 113 .
- Each transfer body 114 delivers the molding material from a respective manifold outlet 120 to a respective delivery body 115 .
- transfer body 114 is held in place against mold plate 102 at shoulder 125 ; as such, thermal expansion of transfer body 114 occurs in the direction of deliver body 115 .
- a telescopic connector 122 is provided between each transfer body 114 and a respective delivery body 115 to slidably connect a transfer body 114 to a respective delivery body 115 and to absorb the forward heat expansion growth of transfer body 114 while also allowing fluid communication between transfer body 114 and a respective delivery body 115 .
- the specific location of telescopic connector 122 is exemplary and is not intended to limit the scope of the present disclosure.
- transfer body 114 is fixedly connected to delivery body 115 and a telescopic connector is provided between transfer body 114 and manifold 113 .
- delivery body, transfer body, and manifold are all fixedly connected and a telescopic connector is provided between manifold and inlet as depicted in U.S. Pat. No. 5,494,433, which is incorporated in its entirety by reference.
- delivery body, transfer body, manifold, and inlet are all fixedly connected, and sealing between the aforesaid components is created by calculating the thermal expansion of each component to create the desired sealing load.
- transfer body 114 delivers the molding material from a respective manifold outlet 120 to a delivery body 115 .
- cavities 108 of edge-gated injection molding apparatus 100 are arranged in a three by one array, that is, an array having three columns and one row, with cavity 108 on the left (as viewed on page) being in the first column F and cavity 108 on the right (as viewed on page) being in the third or last column L, and cavity 108 located in between the first column F and the last column L being the second or middle column M (see FIG. 1A ).
- injection molding apparatus 100 has a plurality of rows extending into, or out of the page view of FIG.
- each delivery body provides molding material to a plurality of mold cavities, similar to the embodiment discussed below having regard to FIG. 4 .
- the cavity in the first column F and the cavity in the middle column M are considered to be adjacent to each another, and the cavity in the last column L and the cavity in the middle column M are also considered to be adjacent to each other.
- delivery body 115 is a unidirectional delivery body 115 A that is positioned outside of the first column F of the array.
- Unidirectional delivery body 115 A delivers molding material generally in one direction (i.e., towards mold cavity 108 ) and is provided with a uni-molding material channel or uni-channel 129 in fluid communication with transfer channel 123 via telescopic connector 122 .
- a tip, or tip assembly 130 is coupled to unidirectional delivery body 115 A at a downstream end uni-channel 129 for delivering a stream of molding material to cavity 108 in the first column F of the array via gate 109 A.
- the delivery body 115 is another unidirectional delivery body 115 A that is positioned outside of the last column L of the array for delivering a stream of molding material to cavity 108 in the last column L of the array via gate 109 B.
- each cavity insert 103 is provided with two gates 109 A, 109 B.
- a bidirectional delivery body 115 B which delivers molding material in substantially opposite directions, is positioned between adjacent columns of the array.
- a bidirectional delivery body 115 B is positioned between the first and middle cavities 108 of the array, and another bidirectional delivery body 115 B is positioned between the middle and the third cavities 108 of the array.
- Bidirectional delivery body 115 B has an inlet 131 , in fluid communication with a respective transfer channel 123 via telescopic connector 122 .
- Inlet 131 divides into two bi-molding material channels or bi-channels 132 which extend in generally opposite directions, specifically a first bi-channel 132 A and a second bi-channel 132 B which may be referred to collectively as bi-channel 132 .
- a tip assembly 130 is coupled to each side of bidirectional delivery body 115 B.
- the tip assembly 130 coupled to the left side of bidirectional delivery body 115 B delivers a stream of molding material to gate 109 B on the right side of cavity 108 in the first column F whereas the tip assembly 130 coupled to the right side of bidirectional delivery body delivers a stream of molding material to gate 109 A on the left side of cavity 108 in the middle column M.
- the tip assembly 130 coupled to the left side of bidirectional delivery body 115 B delivers a stream of molding material to gate 109 B on the right side of cavity 108 in the middle column M whereas the tip assembly 130 coupled to the right side of bidirectional delivery body delivers a stream of molding material to gate 109 A on the left side of cavity 108 in the last column L.
- each cavity 108 of the array receives a stream of molding material from two delivery bodies 115 ; one stream from a bidirectional delivery body 115 B and the other stream from either a bidirectional delivery body 115 B (as is the case for cavity 108 in the middle column M of the array) or from a unidirectional delivery body 115 A (as is the case for cavity 108 in the first F and last L columns of the array). That is, the delivery bodies 115 are positioned such that the pressure from the melt entering cavity 108 via gate 109 A substantially balances the pressure from the melt entering cavity 108 via gate 109 B.
- the number of columns in the array can include n columns by m rows, where n is an integer greater than 1, such that a respective unidirectional delivery body 115 A is positioned outside each of the first F and last L columns of the array and a respective one of n ⁇ 1 bidirectional delivery bodies 115 B is positioned between adjacent columns of the array.
- each array has one first column F, one last column L, and 0 or more middle columns M.
- cavities 108 in the first F, last L and middle M column F of the same row, and respective tip assemblies associated therewith are considered to be in-line with one another.
- Such an arrangement of cavities 108 and delivery bodies 115 allows for close pitch spacing and higher cavitational density, which in turn increases the number of molded articles produced during each injection cycle.
- tip assembly includes a tip body 134 that is slidably received in a bore 135 in a gate seal 136 such that the two pieces are substantially coaxial.
- An example of tip assembly 130 is disclosed in U.S. patent application 61/612,149 which is incorporated herein by reference.
- tip body 134 may be formed from a thermally conductive material, such as beryllium copper
- gate seal 136 may be formed from a less thermally conductive material, such H13 steel. (Beryllium copper and H13 steel are provided by way of example and not limitation)
- a downstream end of gate seal 136 includes a face seal surface 137 that contacts and seals against a first sealing surface 138 of cavity insert 108 .
- Gate seal 136 further includes a circumferential, seal surface 139 that contacts and seals against a corresponding second sealing surface 140 of cavity insert 108 .
- Second sealing surface 140 is located within counter bore that surrounds each gate 109 of cavity insert 108 .
- An upstream surface of tip body 134 and an upstream surface of its corresponding gate seal 136 are slidably disposed against a respective outside, or outlet surface 141 of delivery body 115 and are otherwise not directly attached or secured thereto. Such an arrangement maintains proper alignment between tip assembly 130 and gate 109 regardless of thermal expansion of the heated components of edge-gated injection molding system 100 .
- thermal expansion of delivery body 115 applies pressure against tip body 134 and gate seal 136 to bear pressure between face seal surface 137 and first sealing surface 138 of cavity insert 103 .
- delivery body 115 is a bidirectional delivery body 115 B thermal expansion of bidirectional delivery body 115 B bears pressure upon both the face seal surface 137 associated with the tip assembly 130 on the left side of bidirectional delivery body 115 B and the face seal surface 137 associated with the tip assembly 130 on the right side of bidirectional delivery body 115 B such that bidirectional delivery body 115 B is held in place between respective left and right tip assemblies 130 associated therewith.
- a backup pad 142 which may be similar to support disk 128 described above, is provided in a pocket 133 in cover plate between unidirectional delivery body 115 A and cover plate 104 . Similar to pocket 119 described above, pocket 133 creates an insulating air space around delivery bodies 115 . Backup pad 142 creates a surface upon which unidirectional delivery body 115 A applies force as a result of heat expansion of unidirectional delivery body in order to maintain a seal between unidirectional delivery body 115 A and tip assembly 130 . Back up pad 142 further serves to prevent unidirectional delivery body 115 A from shifting away from cavity insert 103 as a result of injection pressure.
- a spacer 145 is provided in pocket 133 between each delivery body 115 and cover plate 104 .
- Spacer 145 may also be used as a support to prevent downward movement (as viewed on page) of delivery body 115 as a result of injection pressure.
- spacer 145 may also be used to laterally position (as viewed on page) delivery body 115 relative to a respective cavity insert 103 by, for example, engaging spacer 145 with a shoulder in each of cover plate 104 and delivery body 115 .
- spacer 145 locates the height of delivery body 115 , whereas a dowel engages with delivery body 115 and cover plate 104 to maintain lateral positioning (as viewed on page) of delivery body 115 relative to a respective cavity insert 103 .
- manifold molding material channel 118 is sized such that manifold outlet 120 , in fluid communication with a unidirectional delivery body 115 A, has a cross-sectional area that is smaller than the cross sectional area of manifold outlet 120 in fluid communication with bidirectional delivery body 115 B. This is done in order to encourage a greater flow of molding material to bidirectional delivery body 115 B which supplies molding material to two tip assemblies 130 .
- the cross sectional area of manifold outlet 120 in fluid communication with a bidirectional delivery body 115 B is substantially double the size of the cross sectional area of manifold outlet 120 in fluid communication with unidirectional delivery body 115 A.
- manifold outlets 120 in fluid communication with unidirectional delivery body 115 A and outlets 120 in fluid communication with bidirectional delivery body 115 B are equally sized such that molding material flow to bidirectional delivery body 115 B is equal to that of molding material flow to unidirectional delivery body 115 A.
- FIG. 2 is a section view of a two cavity edge-gated injection molding apparatus in accordance with an embodiment hereof, and is generally indicated by reference numeral 200 , features and aspects of which can be used accordingly with the other embodiments, and FIG. 2A is a schematic of the arrangement of components of FIG. 2 .
- transfer body 114 and delivery bodies 115 are instead integrally connected to form a combined, or combined delivery body 215 .
- combined delivery body 215 is fixed at an upstream end thereof by flange 224 (similar to transfer body 114 (as shown by FIG.
- a spacer is not necessary for maintaining alignment between combined delivery body 215 and tip assembly 130 , instead, to maintain alignment between the downstream end of uni-channel 229 and downstream end of bi-channel 232 relative to a channel 143 of a respective tip assembly 130 , the length of combined delivery body 215 is calculated such that, in operation, heat expansion of combined each delivery body 215 brings the downstream end of uni-channel 229 and bi-channel 232 into alignment with channel 143 of a respective tip assembly 130 .
- the cavities 108 of edge-gated injection molding apparatus 200 is laid out in a two by one array, that is, an array having two columns and one row, with cavity 108 on the left (as viewed on page) being the first column F and cavity 108 on the right (as viewed on page) being the second or last column L of the array.
- cavity 108 in the first column F of the array and cavity 108 in the last column L of the array are considered to be adjacent to each another.
- combined delivery body 215 is a unidirectional combined delivery body 215 A that is positioned outside of the first column F of the array.
- Unidirectional combined delivery body 215 A is provided with a uni-channel 229 in fluid communication with a manifold outlet 220 .
- a tip assembly 130 is coupled to a downstream end of unidirectional combined delivery body 215 for delivering a stream of molding material to cavity 108 in the first column F of the array via gate 109 A.
- delivery body 215 is another unidirectional combined delivery body 215 that is positioned outside of the last column L of the array for delivering a stream of molding material to cavity 108 in the last column L of the array via gate 109 B.
- each cavity insert 103 is provided with two gates 109 A, 109 B.
- combined bidirectional delivery body 215 B is positioned between cavity 108 in the first column F of the array and cavity 108 in the last column L of the array.
- combined bidirectional delivery body 115 B has two inlets 231 A and 231 B, with inlet 231 A being in fluid communication between a respective manifold outlet 220 and first bi-channel 232 A, and inlet 231 B being in fluid communication between a respective manifold outlet 220 and second bi-channel 232 B.
- a tip assembly 130 is coupled to each side of combined bidirectional delivery body 215 B.
- Tip assembly 130 coupled to the left side of combined bidirectional delivery body 215 B delivers a stream of molding material to gate 109 B on the right side of cavity 108 in the first column F of the array
- tip assembly 130 coupled to the right side combined bidirectional delivery body 215 B delivers a stream of the molding material to mold gate 109 A on the left side of mold cavity 108 in the last column L of the array.
- each cavity 108 of the array receives a stream of molding material from two delivery bodies 215 ; one stream from a bidirectional delivery body 215 B and the other from a unidirectional delivery body 215 A.
- manifold 213 is configured such that the single stream of molding material entering manifold 113 via manifold inlet 112 is divided into four manifold outlets 220 , each of which having substantially the same cross-sectional area.
- manifold 113 is configured such that molding material is divided substantially evenly between each manifold outlet 220 and subsequently each gate 109 .
- FIG. 3 is a section view of a two cavity edge-gated injection molding apparatus in accordance with an embodiment hereof and is generally indicated by reference numeral 300 , features and aspects of which can be used accordingly with the other embodiments, and FIG. 3A is a schematic of the arrangement of components of FIG. 3 .
- transfer body 114 and delivery body 115 are separate pieces which are coupled together via telescopic connector 122 .
- manifold 113 is configured such that molding material entering manifold 113 via manifold inlet 112 is divided evenly between each of four manifold outlets 120 .
- transfer body 114 is provided to deliver molding material from a respective manifold outlet 114 to a respective delivery body 115 .
- 108 of edge-gated injection molding apparatus 300 are laid out in a two by one array, that is, an array having two columns and one row, with cavity 108 on the left (as viewed on page) being the first column F of the array, and cavity 108 on the right (as viewed on page) being the second or last column L of the array.
- cavity 108 in the first column F of the array and cavity 108 in the last column L of the array are considered to be adjacent to each another.
- the delivery body is a unidirectional delivery body 315 A that is positioned outside of the first column F of the array.
- Unidirectional delivery body 315 A is provided with a uni-channel 329 in fluid communication with transfer body channel 123 .
- a tip assembly 130 is coupled to a downstream end of unidirectional delivery body 115 A for delivering a stream of molding material to the mold cavity 108 in the first column F of the array via gate 109 A.
- the delivery body is another unidirectional delivery body 315 A that is positioned outside of the last column L of the array for delivering a stream of molding material to the mold cavity 108 in the last column L of the array via gate 109 B.
- each cavity insert 103 is provided with two gates 109 A, 109 B].
- bidirectional delivery body 315 B is positioned between adjacent columns of the array.
- a bidirectional delivery body 315 B is positioned between cavity 108 in the first column F of the array and cavity 108 in last column L of the array.
- bidirectional delivery body 315 B has a two of inlets 331 A, and 331 B each of which is in fluid communication between a respective bi-molding material channel 132 A, 132 B, and a respective transfer channel 123 provided for in a separate transfer body 114 .
- a tip assembly 130 is coupled to each side of bidirectional delivery body 315 B.
- Tip assembly 130 is coupled to the left side of bidirectional delivery body 315 delivers a stream of molding material to gate 109 B on the right side of mold cavity 108 in the first column F of the array, tip assembly 130 coupled to the right side of bidirectional delivery body 315 delivers a stream of the molding material to mold gate 109 A on the left side of cavity 108 in the last column L of the array.
- each cavity 108 of the array receives a stream of molding material from two delivery bodies; one from bidirectional delivery body 315 B and the other from a unidirectional delivery body 315 A.
- each outlet 120 not only is a single molding material stream divided into four respective equally sized manifold outlets 120 (two per mold cavity) greater control of the molding material exiting each outlet 120 is achieved by providing a separate transfer body 114 for delivering molding material to each tip assembly 130 and subsequently each gate 109 .
- bidirectional delivery body 315 B delivers a greater amount of molding material to gate 109 B of mold cavity 108 in the first column F of the array than to gate 109 A of mold cavity 108 in the last column L of the array, than the temperature of transfer body 114 associated with gate 109 B of cavity 108 of the first column F of the array can be decreased which will increase the viscosity of molding material flowing therethrough.
- the higher viscosity material will alter the balance of molding material flow between tip assembly 130 associated with gate 109 B of cavity 108 in the first column F of the array and tip assembly 103 associated with gate 109 A of cavity 108 in the last column L of the array such that less molding material flows from tip assembly 130 associated with gate 109 B of cavity 108 of the first column F of the array which can balance the fill rate between adjacent cavities 108 .
- FIG. 4 is a bottom view of delivery bodies and molded articles molded thereby in accordance with an embodiment of the present disclosure removed from the injection molding system, features and aspects of which can be used accordingly with the other embodiments
- FIG. 4A is a schematic of the arrangement of components of FIG. 4 .
- molded articles 446 are shown in place of cavity inserts/cavities.
- molded articles 446 would be formed in respective cavities 408 , shown in FIG. 4A which are functionally similar to cavities 108 discussed in the previous embodiments.
- the specific configuration of delivery bodies 415 , tip assemblies 130 in the current embodiment are similar to injection manifolds etc. depicted in U.S.
- cavities 408 are laid out in an array of three columns by four rows. Such an arrangement is similar to that of FIG. 1 ; however rather than feed a single cavity mold cavity 108 , in the case of unidirectional delivery body of FIG. 1 , or two cavities 108 , in the case of bidirectional delivery body of FIG. 1 , in the embodiment of FIG. 4 each unidirectional delivery body 415 A feeds four cavities 408 and each bidirectional delivery body 415 B feeds eight cavities 408 , more specifically, four cavities 408 positioned on the left side of bidirectional delivery body 415 B and four cavities 408 positioned on the right side of bidirectional delivery body 415 B.
- unidirectional delivery body 415 A has four tip assemblies 430 , all pointing in substantially same direction, each tip assembly 430 for delivering moldable material to a different cavity 108 of a column of cavities 108 and bidirectional delivery body 415 B has four rows of tip assemblies 430 , each row having two tip assemblies 430 , tip assemblies 430 of each row are pointing in substantially opposite directions. Similar to the embodiment of FIG. 3 , each unidirectional delivery body 415 A is in fluid communication with a single transfer body (not shown in FIG.
- each bidirectional delivery body 415 B has two inlets 431 A, 431 B, with each inlet 431 A, 431 B being positioned along a centerline 447 of bidirectional delivery body 415 , and in fluid communication a separate transfer body 414 , one transfer body 114 for providing molding material to cavities 408 positioned on the left side of bidirectional delivery body 415 B via inlet 431 A, and the other to provide molding material to cavities 408 positioned on the right side of bidirectional delivery body 415 B via inlet 431 B.
- Positioning inlets 431 A, 431 B along centerline 447 is advantageous in that it allows the width W of bidirectional delivery body 415 B to be narrower than that of bidirectional delivery body 315 B of FIG.
- inlets 331 A, and 331 B are positioned on different sides of the centerline 447 of bidirectional delivery body 315 B.
- reducing the width W of bidirectional delivery body 415 B allows a closer pitch spacing between adjacent columns of the array, thus increasing the overall cavitational density of the injection molding apparatus.
- the width W of bidirectional delivery body 315 B is substantially the same as that of unidirectional delivery body 315 A.
- a manifold (not shown in FIG.
- each delivery body inlet whether associated with a unidirectional delivery body 415 A or a bidirectional delivery body 415 B, receives substantially 50% of the molding material required to fill four molded articles 446 from a respective manifold outlet (not shown) via a respective transfer body (also not shown).
- FIG. 5A is a perspective view of the bidirectional delivery of FIG. 4
- FIG. 5B is sectional view of the bidirectional delivery body of FIG. 4 taken along line B-B
- FIG. 5C is sectional view of the bidirectional delivery body of FIG. 4 taken along line C-C
- FIG. 5D is a sectional view of the bidirectional delivery body of FIG. 4 taken along line D-D
- FIG. 5E is a sectional view of the bidirectional delivery body of FIG. 4 taken along line E-E.
- bidirectional delivery body 415 B is provided with a network of bi-molding material channels.
- molding material entering inlet 431 A is directed into a primary channel 532 A (see FIG. 5B and FIG. 5D ) that extends along the center-line 447 of bidirectional delivery body 415 B.
- primary channel 532 A turns away from center line 447 and branches into two secondary channels 532 B′, 532 B′′ extending in substantially opposite directions (secondary molding material channels 532 B′, 532 B′′ are generically referenced as secondary channel 532 B) (see FIG. 5C and FIG. 5D ).
- each secondary channel 532 B molding material experiences a level change, as shown at 548 , and branches into two tertiary channels 532 C′, 532 C′′ extending in substantially opposite directions (see FIG. 5B , FIG. 5D , and FIG. 5E ) positioned beneath a respective secondary molding material channel 532 B′, 532 B′′ (tertiary channels 532 C′, 532 C′′ are generically referenced as tertiary channel 532 C).
- each tertiary channel 532 C reorients the flow of molding material through an outlet 549 (see FIG.
- bidirectional delivery body 415 B is manufactured from a solid block, and primary, secondary, and tertiary channels 532 A, 532 B, 532 C are formed as a series of bores extending into bidirectional delivery body 415 B, and to direct the flow of molding material, a plurality of plugs, such as plug 554 , which are inserted in to the bores that define respective primary, secondary, and tertiary channels 532 A, 532 B, 532 C.
- tip assembly 430 further includes a diverter block 451 secured to bottom surface 450 of bidirectional delivery body 415 B.
- Diverter block 451 has a channel 452 extending therethrough that reorients the flow of molding material through a 90° rotation from the bottom of bidirectional delivery body 515 B to tip body channel 438 .
- a wedge 453 is also secured to bottom surface 450 of bidirectional delivery body 415 B which bears against opposite facing tip assemblies 430 .
- wedge 452 bears against opposing diverter blocks 450 (diverter block 450 associated with the left side of bidirectional delivery body 415 B and diverter body 450 associated with the right side of bidirectional delivery body 415 B) to maintain a fluid seal between diverter block channel 452 and tip body channel 438 .
- molding material entering inlet 431 B and flows through a network of bi-molding material channels that are oriented 180 degrees to the network of bi-molding material channels 432 associated with inlet 431 A.
- unidirectional delivery bodies 415 have a channel arrangement similar to the channel arrangement in fluid communication with one of inlets 431 A, and 431 B. Referring to unidirectional delivery body 414 positioned outside the first column F of the array, to feed molding material to the mold cavities 408 on the right side of unidirectional delivery body 415 A, molding material enters an inlet positioned similar on unidirectional delivery body 415 A to inlet 431 B of bidirectional delivery body 415 B and flows through the network of uni-molding material channels to tip assemblies 130 in fluid communication with gates 109 A on the right side of respective mold cavities 408 in the first column F of the array.
- unidirectional delivery body 414 positioned outside the first column L of the array, to feed molding material to the four mold cavities 408 on the left side of unidirectional delivery body 415 A, molding material enters an inlet positioned similar on unidirectional delivery body 415 A to inlet 431 B of bidirectional delivery body 415 B and flows through the network of uni-molding material channels to tip assemblies 130 in fluid communication with gates 109 B on the left side of respective mold cavities 408 in the last column L of the array.
- FIG. 5F is a perspective view of bidirectional delivery body 415 B of FIG. 4 depicting four tip assemblies 430 positioned on the right side of bidirectional delivery body 415 B and two transfer bodies 414 , one coupled to each inlet 431 A, 431 B.
- a center plug, or plug 556 is provided in bidirectional delivery body 415 B to facilitate placement of two inlets 431 A, 431 B along centerline 447 of delivery body 415 B rather than back to back or placement of each inlet 331 A, 331 B in-line between adjacent mold cavities 108 as shown in FIG. 3 .
- FIG. 6 which is a perspective view of plug 556 depicted in FIGS. 5A-D with FIG. 6A being a section A-A through FIG. 6 .
- Plug 556 has a cylindrical body portion 557 that is received in a corresponding bore 558 in bidirectional delivery body 415 B.
- a locating flange 559 extends from body portion 557 to mate with a corresponding feature in a mold plate, (such as mold plate 102 shown in FIG. 1 ) to assist in positioning bidirectional delivery body 415 B.
- Plug 556 defines a junction 662 between each primary molding material channel 532 A and the pair of secondary molding material channels 5323 , 532 B′′ extending from a downstream end of each primary molding material channel 532 A.
- Junction 662 includes a first interconnecting channel 664 A, a second interconnecting channel 664 B, a first segment of primary channel 665 A, a second segment of primary channel 665 B, a first segment of secondary channel 667 A, and a second segment of secondary channel 667 B, first segment of primary channel 665 A forming a portion of the primary channel 532 A of the one of the networks of channels 532 , first segment of secondary channel 667 A forming a portion of secondary channel 532 B, of the other of the networks of channels 532 , first interconnecting channel 664 A interconnecting first segment of primary channel 665 A with first segment of secondary channel 667 A, second segment of primary channel 665 B forming a portion of the primary channel 532 A of the other of the networks of channels 532 , second segment of secondary channel 667 B forming a portion of secondary channel 532 B of the other of the networks of channels 532 , second interconnecting channel 664 B interconnecting second segment of primary channel 665 B with second segment of secondary channel 667
- Plug 556 is a unitary or one piece plug manufactured by an additive manufacturing process such as laser sintering or the like.
- plug 556 may be manufactured from two halves that are brazed or otherwise integrally formed together, with one half of plug 556 having the channel geometry shown in FIG. 6A and the other half or plug 556 having a corresponding mirrored geometry such that complete the peripheral boundary of the portion of primary molding material channel 532 A and secondary molding material channels 532 B′, 532 B′′ are formed in plug 556 . That is, each half of plug 556 includes a network of troughs such that when the two halves combined to form plug 556 , the network of troughs defined the channels of junction 662 .
- FIG. 7 is a perspective view of an alternative embodiment of a center plug, or plug 756 with FIG. 7A being a bottom view of FIG. 7 .
- Plug 756 of FIG. 7 is similar to plug 556 of FIG. 6 , however, in the embodiment of FIG. 7 plug 756 is a half plug having the channel geometry shown in FIG. 7A and bore 558 having a corresponding mirrored geometry such that bore in the delivery body completes the peripheral boundary of the portion of primary molding material channel 532 A and secondary molding material channels 532 B′, 532 B′′ are formed when plug 756 is installed in bore 558 .
- plug 756 includes a network of troughs 769 such that when plug 756 is installed in bore 558 , the network of troughs 769 combines with a corresponding network of troughs (not shown) of bore 558 to define the channels of junction 662 .
- plug 556 , 756 may be made from a material that is the same or different than that of delivery body. Further plug 556 , 756 can be integrally or, alternatively removably installed in the delivery body.
- FIG. 8 is a top view of an eight cavity edge-gated injection molding apparatus in accordance with an embodiment hereof, generally indicated by reference numeral 800 , in which bidirectional delivery bodies 415 B are also used as unidirectional delivery bodies.
- FIG. 8A is a section view of FIG. 8 taken along line A-A.
- FIG. 8B is a perspective view of a portion of injection molding apparatus 800 shown with cavity inserts 803 and support inserts removed.
- FIG. 8C is the perspective view of FIG. 8B shown with manifold 813 and inlet 812 removed.
- FIG. 8D is a perspective view of bidirectional delivery body 415 B and associated cavity inserts 803 .
- cavities 808 of edge-gated injection molding apparatus 800 are laid out in a two by four array, that is, an array having two columns and four rows, with the four cavities 808 on the left (as viewed on page) being the first column F of the array and the four cavities 808 on the right (as viewed on page) being the second or last column L of the array.
- cavity 808 of a respective row in the first column F and cavity 108 of the same respective row in the last column L are considered to be adjacent to each another.
- bidirectional delivery bodies 415 B are also used as unidirectional delivery bodies 415 will be referred to as unidirectional delivery body/bodies 415 C.
- Unidirectional delivery body 415 C can have the same structure as bidirectional delivery body 415 B as discussed having regard to the embodiment of FIG. 4 .
- unidirectional delivery body 415 C of FIG. 8 is fed molding material via a respective transfer body 414 to one of inlets 431 A, 431 B and the other of 431 A, 431 B is not fed any molding material, rendering the tips being fed by the latter inlet unused.
- molding material enters inlet 431 B and flows through the network of molding material channels (similar to channels 532 of FIG. 5A to FIG. 5E ) to tip assemblies 430 in fluid communication with respective gates 809 A on the left side of mold cavities 808 in the first column F of the array.
- unidirectional delivery body 415 C positioned outside the last column L of the array, to feed molding material to the four mold cavities 408 on the left side of unidirectional delivery body 415 C, molding material enters inlet 431 A and flows through the network of molding material channels (opposite to channels 532 of FIG. 5A to FIG. 5E ) to tip assemblies 430 in fluid communication with respective gates 809 B on the right side of respective mold cavities 808 in the last column L of the array.
- each cavity insert 803 is provided with two gates 809 A and 809 B.
- bidirectional delivery body 415 B is positioned between cavities 808 in the first column F of the array and cavities 808 in the last column L of the array.
- bidirectional delivery body 415 B has two inlets 431 A and 431 B, to feed molding material to the mold cavities 808 on the left side of bidirectional delivery body 415 B, molding material enters inlet 431 A and flows through the network of molding material channels (similar to channels 532 of FIG. 5A to FIG.
- manifold 813 receives a stream of molding material via inlet 812 and divides it evenly between four outlets (not shown in FIG. 8 and FIG. 8A to FIG. 8D ), with one outlet being in fluid communication with inlet 431 B of unidirectional delivery body 425 C positioned outside the first column F of the array, one outlet being in fluid communication with inlet 431 A of unidirectional delivery body 425 C positioned outside the last column L column of the array and the remaining two outlets in fluid communication with respective inlets 431 A and 431 B of bidirectional delivery body 415 B.
- each cavity 808 receives a stream of molding material from two delivery bodies 415 ; one stream from a bidirectional delivery body 415 B and the other from a unidirectional delivery body 815 C.
- injection molding apparatus 800 includes support inserts 860 .
- one column of four support inserts 860 is positioned relative to unidirectional delivery body 415 C that is outside of the first column F of the array, and another column of four support inserts is positioned relative to unidirectional delivery body 415 C that is outside of the last column L of the array.
- the pitch spacing of support inserts 860 is equal to that of cavity inserts 803 .
- Support inserts 860 have an outer profile similar to that of cavity inserts 803 and would be received in a corresponding bore in a mold plate, such as mold plate 102 shown in FIG.
- Support inserts 860 are used as place holders to enable the use of bidirectional delivery bodies 415 , as unidirectional delivery bodies 415 C.
- support inserts 860 are made from the same material as cavity inserts 803 , and also have the same internal geometry as cavity inserts 803 thus allowing a respective support insert 860 to be used as a spare cavity insert 803 in the event that a cavity insert 803 becomes damaged.
- tip assembly 430 on the left side of unidirectional delivery body 415 C applies force against support insert 860
- tip assembly 430 on the right side of applies force against cavity insert 803 such that unidirectional delivery body 415 C is held in place between cavity inserts 803 in the first column of the array and support insert 860 by opposite facing tip assemblies 430
- tip assembly 430 associated with support insert 860 has a blank tip body 861 , that is blank tip body 861 does not have a melt channel extending therethrough.
- tip and delivery body arrangements are shown by way of example and not limitation. Further non-limiting examples of tip and delivery body arrangements can be found in the following examples, U.S. Pat. No. 4,981,431, which is incorporated by reference herein, depicts a one piece tip that is threadably coupled to an edge gating nozzle body that creates face seal with a corresponding cavity insert 103 . In this arrangement the tip can be said to be fixed to a delivery body and slidable relative to a corresponding cavity insert.
- tip assembly is a two piece injection tip that is threadably retained to delivery body by way of a separate transfer seal, such an arrangement can be found in U.S. Pat. No. 7,179,081 also incorporated by reference herein.
- the tip can be considered fixed to the delivery body by way of a transfer seal, and is also fixed to cavity insert 103 by way of the circumferential engagement between transfer seal sealing diameter and cavity insert bore.
- a tip seal arrangement such as depicted in U.S. Pat. No. 7,794,228 which is incorporated herein by reference, can also be used in embodiments hereof without diverting from the scope of the disclosure. While tip assemblies 130 are shown projecting at a 90° angle to the axial centerline 110 of each cavity 108 , tip assemblies may also project at an angle to axial centerline in embodiments where it can be disadvantageous to inject molding material directly at the mold core.
- an apparatus can use a combination of combined delivery body 115 A, 115 B and transfer body 114 connected to bidirectional delivery body 115 B or unidirectional delivery body 115 A.
- combined delivery body 115 A, 115 B can be replaced by transfer body 114 connected to bidirectional delivery body 115 B or unidirectional delivery body 115 A, or vice versa.
- the rows and columns do not necessarily have to be horizontal or vertical.
- the term array also includes a sub-array of a larger array.
- an injection molding apparatus may have 96 cavities laid out in an eight by twelve array (eight columns and twelve rows) which is made up of six sub arrays, each sub array having 16 cavities arranged in four columns by four rows of cavities or other suitable combination of sub arrays.
- the breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the appended claims and their equivalents. It will also be understood that each feature of each embodiment discussed herein, and of each reference cited herein, can be used in combination with the features of any other embodiment. All patents and publications discussed herein are incorporated by reference herein in their entirety.
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Abstract
Description
- This application is a continuation of Ser. No. 14/424,697 with a § 371(c)(1), (2) date of Feb. 27, 2015, now U.S. Pat. No. 9,227,351, which is a national phase entry of PCT/CA2013/000745 filed Aug. 28, 2013, which claims the benefit of U.S. Appl. No. 61/693,876 filed Aug. 28, 2012, the disclosures of which are incorporated by reference herein in their entirety.
- The disclosure relates generally to an injection molding system and, in particular, to an edge-gated injection molding system.
- Edge gating is commonly used in the manufacture of slender elongate molded articles such as pipettes or a syringe barrels. The cavity defining the molded article usually has only one gate through which molding material flows in a direction that is generally transverse to the longitudinal axis of the molded article. Pressure within the cavity from molding material flowing through the gate on only one side of the part can adversely affect part filling and/or part geometry. For example, when examining the fill rate of such parts, the side of the part on which the gate is located generally fills first, thus creating an angled flow front as the molding material advances away from the gate. Further, if injection pressure is high enough, the mold core, which defines the inside of the molded article, can be deflected away from the gate. This problem is exacerbated in molded articles that are particularly long, or have a slender core that is not supported at its distal end. The result of such core deflection is molded articles having uneven wall thickness. In molding applications, such as pipette molding and syringe barrel molding, this uneven wall thickness may cause non-uniform part shrinkage which may result in volumetric discrepancies between molded parts as well as an overall increase in the number of defect parts which do not conform to the tolerance requirements of the end user.
- One solution to avoiding the aforementioned difficulties with edge gating is to reduce injection pressure and/or increase part fill time; however, this comes at a cost of reduced productivity. Another solution is to inject molding material into each cavity via two mold gates, one on each side of the molded article. Both German patent DE 29902185U and U.S. Pat. No. 7,214,053 disclose edge gating application in which groups of four mold cavities are fed molding material from two sides by groups of four nozzles. The mold cavities are evenly spaced around a first pitch circle and the nozzles are evenly spaced around a second larger pitch circle with the spacing of the nozzles offset by 45 degrees relative to the orientation of the mold cavities. In the resulting arrangement each mold cavity receives molding material from two injection nozzles and each injection nozzle delivers molding material to two mold cavities. While the problem of core shift is reduced in this configuration, the cavitation density of the mold suffers as a result of unused space at the center or the pitch circle. Furthermore, should the cavity/nozzle groupings be increased to, for example, groupings of eight cavities and eight injection nozzles spaced about pitch circles that are used in the above described configuration the cavitation density of the mold is adversely affected as the unused space at the center of each pitch circle increases greatly with an increase in pitch circle diameter.
- As such, a need exists in the art for an edge gating apparatus that reduces the above described problems while effectively using the available space inside the mold.
- An aspect of the embodiments hereof are directed toward an edge gating injection molding apparatus for delivering a moldable material to an array of mold cavities, the array can have a first column and a last column of mold cavities, the edge gating injection molding apparatus comprising: a unidirectional delivery body for delivering a first stream of the moldable material to a different one of each mold cavity of the first column and the last column of mold cavities, via a first location of the different one of each mold cavity of the first column and the last column of mold cavities; and a bidirectional delivery body for delivering a second stream of the moldable material to the different one of each mold cavity of the first column and the last column of mold cavities, via a second location of the different one of each mold cavity of the first column and the last column of mold cavities.
- Another aspect of the embodiments hereof are directed toward an injection molding apparatus comprising: a plurality of cavity inserts arranged in an array having n columns of cavities, each cavity insert can have a pair of opposing mold gates; a unidirectional delivery body in fluid communication with a molding material source, and positioned outside of a first column of the array; another unidirectional delivery body in fluid communication with the molding material source, and positioned outside of the last column of the array; and n−1 bidirectional delivery bodies in fluid communication with the molding material source, each of the n−1 bidirectional delivery bodies positioned between adjacent columns of the array, wherein each cavity can receive molding material from at least one bidirectional delivery body.
- The foregoing and other features and advantages of the disclosure will be apparent from the following description of the disclosure as illustrated in the accompanying drawings. The accompanying drawings, which are incorporated herein and form a part of the specification, further serve to explain the principles of the disclosure and to enable a person skilled in the pertinent art to make and use the disclosure. The drawings are not to scale.
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FIG. 1 is a sectional view of a three cavity edge-gated injection molding apparatus in accordance with an embodiment of the present disclosure. -
FIG. 1A is a schematic of the arrangement of components ofFIG. 1 . -
FIG. 2 is a sectional view of a two cavity edge-gated injection molding apparatus in accordance with another embodiment of the present disclosure. -
FIG. 2A is a schematic of the arrangement of components ofFIG. 2 . -
FIG. 3 is a sectional view of a two cavity edge-gated injection molding apparatus in accordance with another embodiment of the present disclosure. -
FIG. 3A is a schematic of the arrangement of components ofFIG. 3 . -
FIG. 4 is a bottom view of delivery bodies and molded articles molded thereby in accordance with an embodiment of the present disclosure removed from the injection molding system. -
FIG. 4A is a schematic of the arrangement of components ofFIG. 4 . -
FIG. 5A is a perspective view of a bidirectional delivery body ofFIG. 4 . -
FIG. 5B is sectional view of the bidirectional delivery body ofFIG. 5 taken along line B-B thereof. -
FIG. 5C is sectional view of the bidirectional delivery body ofFIG. 5 taken along line C-C thereof. -
FIG. 5D is a sectional view of the bidirectional delivery body ofFIG. 5 taken along line D-D thereof. -
FIG. 5E is a sectional view of the bidirectional delivery body ofFIG. 5 taken along line E-E thereof. -
FIG. 5F is a perspective view of a bidirectional delivery body ofFIG. 4 with transfer bodies and tip assemblies. -
FIG. 6 is a perspective view of a plug removed from a bidirectional delivery body ofFIG. 4 . -
FIG. 6A is sectional view through the plug ofFIG. 6 taken along line A-A thereof. -
FIG. 7 is perspective view of a plug in accordance with another embodiment of the present disclosure removed from a bidirectional delivery body ofFIG. 4 . -
FIG. 7A is a bottom view of the plug ofFIG. 7 . -
FIG. 8 is a top view of an edge-gated injection molding apparatus in accordance with another embodiment. -
FIG. 8A is a section view of the edge-gated injection molding apparatus ofFIG. 8 taken along line A-A. -
FIG. 8B is a perspective view of a portion of the injection molding apparatus ofFIG. 8 . -
FIG. 8C is the perspective view of the edge-gated injection molding apparatus ofFIG. 8 with the manifold and inlet removed. -
FIG. 8D is a perspective view of a bidirectional delivery body from the edge-gated injection molding apparatus ofFIG. 8 . - Specific embodiments of the present disclosure are now described with reference to the figures. In the following description, “downstream” is used with reference to the general direction of mold material flow from an injection unit to a mold cavity of an injection molding system and also to the order of components, or features thereof through which the mold material flows, from an inlet of the injection molding system to a mold cavity, whereas “upstream” is used with reference to the opposite direction. Also, in the following description each of the terms “left”, “right”, “top” and “bottom” is used with reference to the non-limiting orientation of components as shown in the figures. While specific configurations and arrangements are discussed, it should be understood that this is done for illustrative purposes only. A person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the scope of the present disclosure.
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FIG. 1 is a section view of a three cavity edge-gated injection molding apparatus in accordance with an embodiment hereof and is generally indicated byreference numeral 100, features and aspects of which can be used accordingly with the other embodiments.FIG. 1A is a schematic of the arrangement of components ofFIG. 1 . Edge-gated injection molding apparatus includes aback plate 101, amold plate 102, cavity inserts 103, and acover plate 104 all held together by a plurality of sockethead cap screws 105 or the like.Back plate 101,mold plate 102,cover plate 104, andcavity insert 103 may be provided with fluid channels, such asfluid channel 106 called out onmold plate 102, through which a fluid is circulated to maintaininjection molding apparatus 100 at a required processing temperature.Cavity insert 103 is located in abore 107 inmold plate 102 and defines acavity 108 which defines an outside surface of the article being molded.Cavity 108 together with a mold core (not shown) define the general shape of the article being molded byinjection molding apparatus 100. To allow molding material to enter intocavity 108, eachcavity insert 103 is provided with a pair ofgates 109, (gate 109A refers to the gate to the left ofcavity 108 as viewed on page,gate 109B refers to the gate to the right ofcavity 108 as viewed on page,gates gate 109A is at a first location andgate 109B is at a second location, the first and second locations are substantially diametrically opposite one another relative to anaxial center line 110 ofcavity 108. In another embodiment (not shown),gates center line 110 ofcavity 108. Edge-gatedinjection molding apparatus 100 further includes aninlet 112, a manifold 113, a plurality oftransfer bodies 114, and a plurality ofdelivery bodies 115 in the form ofunidirectional delivery bodies 115A andbidirectional delivery bodies 115B. (Unidirectional delivery body/bodies 115A and bidirectional delivery body/bodies 115 are referred to generically as delivery body/bodies 115.) In the current embodiment, each ofinlet 112, manifold 113, transferbodies 114, anddelivery bodies 115 is provided with a heater, such asheater 116 shown ondelivery body 115, in the form of an embedded resistance heater for maintaining each ofinlet 112, manifold 113, transferbodies 114, anddelivery bodies 115 at a required processing temperature. (The number and type of heaters are shown by way of example and not limitation.) In an alternative embodiment (not shown) only some ofinlet 112, manifold 113, transferbodies 114, anddelivery bodies 115 are provided with a heater.Inlet 112, manifold 113, transferbodies 114, anddelivery bodies 115 can be referred to generally as a hot runner system. A molding machine nozzle (not shown) interfaces withinlet 112 atseat 117 to deliver a stream of moldable material under pressure to amanifold channel 118 of themanifold 113.Manifold 113 is located in apocket 119 inmold plate 102, and serves to deliver the molding material stream from the molding machine nozzle (not shown) to each of the plurality oftransfer bodies 114 via arespective manifold outlet 120.Pocket 119 is sized in order to maintain an insulatingair space 121 aroundmanifold 113. In the embodiment shown inFIG. 1 ,manifold 113 delivers the molding material stream frominlet 112 to fourtransfer bodies 114. Eachtransfer body 114 is configured for alignment between atransfer channel 123 and arespective manifold outlet 120 to receive a molding material stream frommanifold channel 118.Transfer body 114 has aflange 124 that sits in acorresponding shoulder 125 of aclearance bore 126 inmold plate 102. Similar to pocket 119 described above, clearance bore 126 creates an insulatingair space 127 betweentransfer body 114 andmold plate 102. Asupport disk 128 is positioned betweenmanifold 113 andback plate 101 to focus the force from manifold heat expansion directly over eachtransfer body 114. During operation, theflange 124 andmold plate shoulder 125 arrangement, together withsupport disk 128 supports the load from heat expansion ofmanifold 113 while still allowing the load frommanifold 113 to be used as a sealing means/force betweentransfer bodies 114 andmanifold 113. Eachtransfer body 114 delivers the molding material from arespective manifold outlet 120 to arespective delivery body 115. As mentioned above,transfer body 114 is held in place againstmold plate 102 atshoulder 125; as such, thermal expansion oftransfer body 114 occurs in the direction of deliverbody 115. Atelescopic connector 122 is provided between eachtransfer body 114 and arespective delivery body 115 to slidably connect atransfer body 114 to arespective delivery body 115 and to absorb the forward heat expansion growth oftransfer body 114 while also allowing fluid communication betweentransfer body 114 and arespective delivery body 115. The specific location oftelescopic connector 122 is exemplary and is not intended to limit the scope of the present disclosure. In an alternative embodiment (not shown)transfer body 114 is fixedly connected todelivery body 115 and a telescopic connector is provided betweentransfer body 114 andmanifold 113. In another embodiment, (also not shown) delivery body, transfer body, and manifold are all fixedly connected and a telescopic connector is provided between manifold and inlet as depicted in U.S. Pat. No. 5,494,433, which is incorporated in its entirety by reference. In yet another embodiment (as shown inFIG. 2 ), delivery body, transfer body, manifold, and inlet are all fixedly connected, and sealing between the aforesaid components is created by calculating the thermal expansion of each component to create the desired sealing load. - As discussed above,
transfer body 114 delivers the molding material from arespective manifold outlet 120 to adelivery body 115. For discussion purposes, in thecurrent embodiment cavities 108 of edge-gatedinjection molding apparatus 100 are arranged in a three by one array, that is, an array having three columns and one row, withcavity 108 on the left (as viewed on page) being in the first column F andcavity 108 on the right (as viewed on page) being in the third or last column L, andcavity 108 located in between the first column F and the last column L being the second or middle column M (seeFIG. 1A ). In an alternative non-limiting embodiment (not shown)injection molding apparatus 100 has a plurality of rows extending into, or out of the page view ofFIG. 1 with each delivery body providing molding material to a plurality of mold cavities, similar to the embodiment discussed below having regard toFIG. 4 . Returning toFIG. 1 , the cavity in the first column F and the cavity in the middle column M are considered to be adjacent to each another, and the cavity in the last column L and the cavity in the middle column M are also considered to be adjacent to each other. Referring tocavity 108 in the first column F of the array,delivery body 115 is aunidirectional delivery body 115A that is positioned outside of the first column F of the array.Unidirectional delivery body 115A delivers molding material generally in one direction (i.e., towards mold cavity 108) and is provided with a uni-molding material channel or uni-channel 129 in fluid communication withtransfer channel 123 viatelescopic connector 122. A tip, ortip assembly 130 is coupled tounidirectional delivery body 115A at adownstream end uni-channel 129 for delivering a stream of molding material tocavity 108 in the first column F of the array viagate 109A. Referring tocavity 108 in the last column L of the array, thedelivery body 115 is anotherunidirectional delivery body 115A that is positioned outside of the last column L of the array for delivering a stream of molding material tocavity 108 in the last column L of the array viagate 109B. - As discussed above, each
cavity insert 103 is provided with twogates gate 109B ofcavity 108 in the first column F of the array, andgate 109A of thecavity 108 in the last column L in the array, abidirectional delivery body 115B, which delivers molding material in substantially opposite directions, is positioned between adjacent columns of the array. In the present embodiment, abidirectional delivery body 115B is positioned between the first andmiddle cavities 108 of the array, and anotherbidirectional delivery body 115B is positioned between the middle and thethird cavities 108 of the array.Bidirectional delivery body 115B has aninlet 131, in fluid communication with arespective transfer channel 123 viatelescopic connector 122.Inlet 131 divides into two bi-molding material channels or bi-channels 132 which extend in generally opposite directions, specifically a first bi-channel 132A and a second bi-channel 132B which may be referred to collectively asbi-channel 132. At a downstream end of each bi-channel 132A, 132B atip assembly 130 is coupled to each side ofbidirectional delivery body 115B. Onetip assembly 130 for delivering a stream of molding material tocavity 108 in one of the adjacent columns of the array, and theother tip assembly 130 for delivering a stream of the molding material tomold cavity 108 in the other of the adjacent columns of the array. Referring to bidirectional delivery body 115B positioned between cavity 108 in the first column F and cavity 108 in the middle column M, the tip assembly 130 coupled to the left side of bidirectional delivery body 115B delivers a stream of molding material to gate 109B on the right side of cavity 108 in the first column F whereas the tip assembly 130 coupled to the right side of bidirectional delivery body delivers a stream of molding material to gate 109A on the left side of cavity 108 in the middle column M. Referring to bidirectional delivery body 115B positioned between cavity 108 in the middle column M and cavity 108 in the last column L, the tip assembly 130 coupled to the left side of bidirectional delivery body 115B delivers a stream of molding material to gate 109B on the right side of cavity 108 in the middle column M whereas the tip assembly 130 coupled to the right side of bidirectional delivery body delivers a stream of molding material to gate 109A on the left side of cavity 108 in the last column L. In such an arrangement each cavity 108 of the array receives a stream of molding material from two delivery bodies 115; one stream from a bidirectional delivery body 115B and the other stream from either a bidirectional delivery body 115B (as is the case for cavity 108 in the middle column M of the array) or from a unidirectional delivery body 115A (as is the case for cavity 108 in the first F and last L columns of the array). That is, thedelivery bodies 115 are positioned such that the pressure from themelt entering cavity 108 viagate 109A substantially balances the pressure from themelt entering cavity 108 viagate 109B. - Given the arrangement of
cavities 108 anddelivery bodies 115, the number of columns in the array can include n columns by m rows, where n is an integer greater than 1, such that a respectiveunidirectional delivery body 115A is positioned outside each of the first F and last L columns of the array and a respective one of n−1bidirectional delivery bodies 115B is positioned between adjacent columns of the array. Accordingly, each array has one first column F, one last column L, and 0 or more middle columns M. In the current embodiment,cavities 108 in the first F, last L and middle M column F of the same row, and respective tip assemblies associated therewith are considered to be in-line with one another. Such an arrangement ofcavities 108 anddelivery bodies 115 allows for close pitch spacing and higher cavitational density, which in turn increases the number of molded articles produced during each injection cycle. - In the current embodiment tip assembly includes a
tip body 134 that is slidably received in a bore 135 in agate seal 136 such that the two pieces are substantially coaxial. An example oftip assembly 130 is disclosed in U.S. patent application 61/612,149 which is incorporated herein by reference. In embodiments hereof,tip body 134 may be formed from a thermally conductive material, such as beryllium copper, andgate seal 136 may be formed from a less thermally conductive material, such H13 steel. (Beryllium copper and H13 steel are provided by way of example and not limitation) A downstream end ofgate seal 136 includes aface seal surface 137 that contacts and seals against afirst sealing surface 138 ofcavity insert 108.Gate seal 136 further includes a circumferential,seal surface 139 that contacts and seals against a corresponding second sealing surface 140 ofcavity insert 108. Second sealing surface 140 is located within counter bore that surrounds eachgate 109 ofcavity insert 108. An upstream surface oftip body 134 and an upstream surface of itscorresponding gate seal 136 are slidably disposed against a respective outside, oroutlet surface 141 ofdelivery body 115 and are otherwise not directly attached or secured thereto. Such an arrangement maintains proper alignment betweentip assembly 130 andgate 109 regardless of thermal expansion of the heated components of edge-gatedinjection molding system 100. - In order to maintain a seal between
tip assembly 130 anddelivery body 115 thermal expansion ofdelivery body 115 applies pressure againsttip body 134 andgate seal 136 to bear pressure betweenface seal surface 137 andfirst sealing surface 138 ofcavity insert 103. Ifdelivery body 115 is abidirectional delivery body 115B thermal expansion ofbidirectional delivery body 115B bears pressure upon both theface seal surface 137 associated with thetip assembly 130 on the left side ofbidirectional delivery body 115B and theface seal surface 137 associated with thetip assembly 130 on the right side ofbidirectional delivery body 115B such thatbidirectional delivery body 115B is held in place between respective left andright tip assemblies 130 associated therewith. Ifdelivery body 115 is aunidirectional delivery body 115A abackup pad 142, which may be similar tosupport disk 128 described above, is provided in apocket 133 in cover plate betweenunidirectional delivery body 115A andcover plate 104. Similar to pocket 119 described above,pocket 133 creates an insulating air space arounddelivery bodies 115.Backup pad 142 creates a surface upon whichunidirectional delivery body 115A applies force as a result of heat expansion of unidirectional delivery body in order to maintain a seal betweenunidirectional delivery body 115A andtip assembly 130. Back uppad 142 further serves to preventunidirectional delivery body 115A from shifting away fromcavity insert 103 as a result of injection pressure. - In order to locate
delivery bodies 115 withininjection molding apparatus 100, specifically, locating the height of a downstream end ofuni-channel 129 and downstream end ofbi-molding material channel 132 relative to achannel 143 of arespective tip assembly 130, aspacer 145 is provided inpocket 133 between eachdelivery body 115 andcover plate 104.Spacer 145 may also be used as a support to prevent downward movement (as viewed on page) ofdelivery body 115 as a result of injection pressure. In another embodiment (not shown) spacer 145 may also be used to laterally position (as viewed on page)delivery body 115 relative to arespective cavity insert 103 by, for example, engagingspacer 145 with a shoulder in each ofcover plate 104 anddelivery body 115. In a further embodiment (also not shown),spacer 145 locates the height ofdelivery body 115, whereas a dowel engages withdelivery body 115 andcover plate 104 to maintain lateral positioning (as viewed on page) ofdelivery body 115 relative to arespective cavity insert 103. - While it may be desirable to inject even amounts of molding material through each
gate cavity 108, a study undertaken by the applicant has shown that an even divide of molding material between the two gates leading to each cavity is not necessary for at least improving the core shift and flow length phenomenon described above with regard to single sided edge gating. The chart below outlines the effects of molding material distribution between two gates and core shift, and flow length difference. -
Flow Split (molding Flow Length Max Core Max Core material distribution Difference at Shift at 86% Shift at 100% between gates) 86% fill (mm) fill (mm) fill (mm) 0/100 7.1 0.58 0.5 40/60 1.3 0.126 0.148 50/50 0.1 0.001 0.0005 - In the current embodiment manifold
molding material channel 118 is sized such thatmanifold outlet 120, in fluid communication with aunidirectional delivery body 115A, has a cross-sectional area that is smaller than the cross sectional area ofmanifold outlet 120 in fluid communication withbidirectional delivery body 115B. This is done in order to encourage a greater flow of molding material tobidirectional delivery body 115B which supplies molding material to twotip assemblies 130. In the current embodiment the cross sectional area ofmanifold outlet 120 in fluid communication with abidirectional delivery body 115B is substantially double the size of the cross sectional area ofmanifold outlet 120 in fluid communication withunidirectional delivery body 115A. In an alternative embodiment (not shown)manifold outlets 120 in fluid communication withunidirectional delivery body 115A andoutlets 120 in fluid communication withbidirectional delivery body 115B are equally sized such that molding material flow tobidirectional delivery body 115B is equal to that of molding material flow tounidirectional delivery body 115A. -
FIG. 2 is a section view of a two cavity edge-gated injection molding apparatus in accordance with an embodiment hereof, and is generally indicated byreference numeral 200, features and aspects of which can be used accordingly with the other embodiments, andFIG. 2A is a schematic of the arrangement of components ofFIG. 2 . In the current embodiment,transfer body 114 and delivery bodies 115 (as shown byFIG. 1 ) are instead integrally connected to form a combined, or combineddelivery body 215. Rather than using a telescopic link to accommodate for heat expansion, combineddelivery body 215 is fixed at an upstream end thereof by flange 224 (similar to transfer body 114 (as shown byFIG. 1 ) that sits inshoulder 125 of clearance bore 126 inmold plate 102, such that thermal expansion of combineddelivery body 215 occurs in the direction ofcover plate 104. In the absence oftelescopic connector 122, thermal expansion is accommodated by the sliding interface betweentip assembly 130 and combineddelivery body 215. In such an arrangement a spacer is not necessary for maintaining alignment between combineddelivery body 215 andtip assembly 130, instead, to maintain alignment between the downstream end ofuni-channel 229 and downstream end ofbi-channel 232 relative to achannel 143 of arespective tip assembly 130, the length of combineddelivery body 215 is calculated such that, in operation, heat expansion of combined eachdelivery body 215 brings the downstream end ofuni-channel 229 and bi-channel 232 into alignment withchannel 143 of arespective tip assembly 130. - For discussion purposes, in the current embodiment the
cavities 108 of edge-gatedinjection molding apparatus 200 is laid out in a two by one array, that is, an array having two columns and one row, withcavity 108 on the left (as viewed on page) being the first column F andcavity 108 on the right (as viewed on page) being the second or last column L of the array. In this array,cavity 108 in the first column F of the array andcavity 108 in the last column L of the array are considered to be adjacent to each another. Referring tocavity 108 in the first column F of the array, combineddelivery body 215 is a unidirectional combineddelivery body 215A that is positioned outside of the first column F of the array. Unidirectional combineddelivery body 215A is provided with a uni-channel 229 in fluid communication with amanifold outlet 220. Atip assembly 130 is coupled to a downstream end of unidirectional combineddelivery body 215 for delivering a stream of molding material tocavity 108 in the first column F of the array viagate 109A. Referring tocavity 108 in the last column L of the array,delivery body 215 is another unidirectional combineddelivery body 215 that is positioned outside of the last column L of the array for delivering a stream of molding material tocavity 108 in the last column L of the array viagate 109B. - As discussed above, each
cavity insert 103 is provided with twogates gate 109B ofcavity 108 in the first column F of the array and togate 109A ofcavity 108 in the last column L of the array combinedbidirectional delivery body 215B is positioned betweencavity 108 in the first column F of the array andcavity 108 in the last column L of the array. In the current embodiment combinedbidirectional delivery body 115B has twoinlets inlet 231A being in fluid communication between arespective manifold outlet 220 and first bi-channel 232A, andinlet 231B being in fluid communication between arespective manifold outlet 220 and second bi-channel 232B. At a downstream end of each bi-channel 232A, 232B, atip assembly 130 is coupled to each side of combinedbidirectional delivery body 215B.Tip assembly 130 coupled to the left side of combinedbidirectional delivery body 215B delivers a stream of molding material togate 109B on the right side ofcavity 108 in the first column F of the array, whereastip assembly 130 coupled to the right side combinedbidirectional delivery body 215B delivers a stream of the molding material to moldgate 109A on the left side ofmold cavity 108 in the last column L of the array. In such an arrangement eachcavity 108 of the array receives a stream of molding material from twodelivery bodies 215; one stream from abidirectional delivery body 215B and the other from aunidirectional delivery body 215A. - Rather than sizing molding material channels to affect molding material flow distribution between the pair of
gates cavity 108,manifold 213 is configured such that the single stream of moldingmaterial entering manifold 113 viamanifold inlet 112 is divided into fourmanifold outlets 220, each of which having substantially the same cross-sectional area. In thisarrangement manifold 113 is configured such that molding material is divided substantially evenly between eachmanifold outlet 220 and subsequently eachgate 109. -
FIG. 3 is a section view of a two cavity edge-gated injection molding apparatus in accordance with an embodiment hereof and is generally indicated byreference numeral 300, features and aspects of which can be used accordingly with the other embodiments, andFIG. 3A is a schematic of the arrangement of components ofFIG. 3 . Similar to the embodiment ofFIG. 1 transfer body 114 anddelivery body 115 are separate pieces which are coupled together viatelescopic connector 122. Whereas, similar to the embodiment ofFIG. 2 ,manifold 113 is configured such that moldingmaterial entering manifold 113 viamanifold inlet 112 is divided evenly between each of fourmanifold outlets 120. - As discussed above having regard to
FIG. 1 ,transfer body 114 is provided to deliver molding material from arespective manifold outlet 114 to arespective delivery body 115. For discussion purposes, in thecurrent embodiment 108 of edge-gatedinjection molding apparatus 300 are laid out in a two by one array, that is, an array having two columns and one row, withcavity 108 on the left (as viewed on page) being the first column F of the array, andcavity 108 on the right (as viewed on page) being the second or last column L of the array. In this array,cavity 108 in the first column F of the array andcavity 108 in the last column L of the array are considered to be adjacent to each another. Referring tocavity 108 in the first column F of the array, the delivery body is aunidirectional delivery body 315A that is positioned outside of the first column F of the array.Unidirectional delivery body 315A is provided with a uni-channel 329 in fluid communication withtransfer body channel 123. Atip assembly 130 is coupled to a downstream end ofunidirectional delivery body 115A for delivering a stream of molding material to themold cavity 108 in the first column F of the array viagate 109A. Referring to thecavity 108 in the last column L of the array, the delivery body is anotherunidirectional delivery body 315A that is positioned outside of the last column L of the array for delivering a stream of molding material to themold cavity 108 in the last column L of the array viagate 109B. - As discussed above, each
cavity insert 103 is provided with twogates gate 109B ofcavity 108 in the last column L of the array, and togate 109A ofcavity 108 in the last column L of the array,bidirectional delivery body 315B is positioned between adjacent columns of the array. In the present embodiment, abidirectional delivery body 315B is positioned betweencavity 108 in the first column F of the array andcavity 108 in last column L of the array. In the current embodimentbidirectional delivery body 315B has a two ofinlets bi-molding material channel respective transfer channel 123 provided for in aseparate transfer body 114. At a downstream end of each bi-channel 332A, 332B, atip assembly 130 is coupled to each side ofbidirectional delivery body 315B.Tip assembly 130 is coupled to the left side ofbidirectional delivery body 315 delivers a stream of molding material togate 109B on the right side ofmold cavity 108 in the first column F of the array,tip assembly 130 coupled to the right side ofbidirectional delivery body 315 delivers a stream of the molding material to moldgate 109A on the left side ofcavity 108 in the last column L of the array. In such an arrangement eachcavity 108 of the array receives a stream of molding material from two delivery bodies; one frombidirectional delivery body 315B and the other from aunidirectional delivery body 315A. In the current embodiment, not only is a single molding material stream divided into four respective equally sized manifold outlets 120 (two per mold cavity) greater control of the molding material exiting eachoutlet 120 is achieved by providing aseparate transfer body 114 for delivering molding material to eachtip assembly 130 and subsequently eachgate 109. For example, if it is determined thatbidirectional delivery body 315B delivers a greater amount of molding material togate 109B ofmold cavity 108 in the first column F of the array than togate 109A ofmold cavity 108 in the last column L of the array, than the temperature oftransfer body 114 associated withgate 109B ofcavity 108 of the first column F of the array can be decreased which will increase the viscosity of molding material flowing therethrough. Accordingly, the higher viscosity material will alter the balance of molding material flow betweentip assembly 130 associated withgate 109B ofcavity 108 in the first column F of the array andtip assembly 103 associated withgate 109A ofcavity 108 in the last column L of the array such that less molding material flows fromtip assembly 130 associated withgate 109B ofcavity 108 of the first column F of the array which can balance the fill rate betweenadjacent cavities 108. -
FIG. 4 is a bottom view of delivery bodies and molded articles molded thereby in accordance with an embodiment of the present disclosure removed from the injection molding system, features and aspects of which can be used accordingly with the other embodiments, andFIG. 4A is a schematic of the arrangement of components ofFIG. 4 . InFIG. 4 moldedarticles 446 are shown in place of cavity inserts/cavities. Although not shown inFIG. 4 , a person of ordinary skill in the art would understand that moldedarticles 446 would be formed inrespective cavities 408, shown inFIG. 4A which are functionally similar tocavities 108 discussed in the previous embodiments. The specific configuration ofdelivery bodies 415,tip assemblies 130 in the current embodiment are similar to injection manifolds etc. depicted in U.S. patent application 61/612,149 which is incorporated herein by reference. In each of the previous examples mold cavities are laid out in an array having two or more columns and only one row. While this simple arrangement is illustrative of the present disclosure, in order to increase the cavitation density of a mold, the injection molding apparatus can be laid out in array two or more columns and more than one row. - In the embodiment of
FIG. 4 ,cavities 408 are laid out in an array of three columns by four rows. Such an arrangement is similar to that ofFIG. 1 ; however rather than feed a singlecavity mold cavity 108, in the case of unidirectional delivery body ofFIG. 1 , or twocavities 108, in the case of bidirectional delivery body ofFIG. 1 , in the embodiment ofFIG. 4 eachunidirectional delivery body 415A feeds fourcavities 408 and eachbidirectional delivery body 415B feeds eightcavities 408, more specifically, fourcavities 408 positioned on the left side ofbidirectional delivery body 415B and fourcavities 408 positioned on the right side ofbidirectional delivery body 415B. That is,unidirectional delivery body 415A has fourtip assemblies 430, all pointing in substantially same direction, eachtip assembly 430 for delivering moldable material to adifferent cavity 108 of a column ofcavities 108 andbidirectional delivery body 415B has four rows oftip assemblies 430, each row having twotip assemblies 430,tip assemblies 430 of each row are pointing in substantially opposite directions. Similar to the embodiment ofFIG. 3 , eachunidirectional delivery body 415A is in fluid communication with a single transfer body (not shown inFIG. 4 ), and eachbidirectional delivery body 415B has twoinlets inlet centerline 447 ofbidirectional delivery body 415, and in fluid communication aseparate transfer body 414, onetransfer body 114 for providing molding material tocavities 408 positioned on the left side ofbidirectional delivery body 415B viainlet 431A, and the other to provide molding material tocavities 408 positioned on the right side ofbidirectional delivery body 415B viainlet 431B.Positioning inlets centerline 447 is advantageous in that it allows the width W ofbidirectional delivery body 415B to be narrower than that ofbidirectional delivery body 315B ofFIG. 3 , in which inlets 331A, and 331B are positioned on different sides of thecenterline 447 ofbidirectional delivery body 315B. Continuing withFIG. 4 , reducing the width W ofbidirectional delivery body 415B allows a closer pitch spacing between adjacent columns of the array, thus increasing the overall cavitational density of the injection molding apparatus. In the current embodiment the width W ofbidirectional delivery body 315B is substantially the same as that ofunidirectional delivery body 315A. In the current embodiment a manifold (not shown inFIG. 4 ) receives a stream of molding material from a source and divides it into six manifold outlets such that each delivery body inlet, whether associated with aunidirectional delivery body 415A or abidirectional delivery body 415B, receives substantially 50% of the molding material required to fill four moldedarticles 446 from a respective manifold outlet (not shown) via a respective transfer body (also not shown). - Referring to
bidirectional delivery body 415B, as shown schematically inFIG. 4A and also toFIGS. 5A-5E , in whichFIG. 5A is a perspective view of the bidirectional delivery ofFIG. 4 ,FIG. 5B is sectional view of the bidirectional delivery body ofFIG. 4 taken along line B-B,FIG. 5C is sectional view of the bidirectional delivery body ofFIG. 4 taken along line C-C,FIG. 5D is a sectional view of the bidirectional delivery body ofFIG. 4 taken along line D-D, andFIG. 5E is a sectional view of the bidirectional delivery body ofFIG. 4 taken along line E-E. To ensure molding material balance between fourcavities 408,bidirectional delivery body 415B is provided with a network of bi-molding material channels. For example, referring to the fourcavities 408 on the left side ofbidirectional delivery body 415, moldingmaterial entering inlet 431A is directed into aprimary channel 532A (seeFIG. 5B andFIG. 5D ) that extends along the center-line 447 ofbidirectional delivery body 415B. At the downstream end thereof,primary channel 532A turns away fromcenter line 447 and branches into twosecondary channels 532B′, 532B″ extending in substantially opposite directions (secondarymolding material channels 532B′, 532B″ are generically referenced assecondary channel 532B) (seeFIG. 5C andFIG. 5D ). At the downstream end of eachsecondary channel 532B molding material experiences a level change, as shown at 548, and branches into twotertiary channels 532C′, 532C″ extending in substantially opposite directions (seeFIG. 5B ,FIG. 5D , andFIG. 5E ) positioned beneath a respective secondarymolding material channel 532B′, 532B″ (tertiary channels 532C′, 532C″ are generically referenced astertiary channel 532C). At a downstream end thereof, eachtertiary channel 532C reorients the flow of molding material through an outlet 549 (seeFIG. 5B ) which is in fluid communication withtip assembly 430 that is configured to redirect the flow of molding material from abottom surface 450 ofbidirectional delivery body 415B to arespective mold cavity 408 via agate 109B. That is, in the embodiment ofFIGS. 4, 4A, and 5A-5F ,primary channel 532A,secondary channels 532B, andtertiary channels 532C form a network ofchannels 532 and each network ofchannels 532 is fed by oneinlet 431; eachunidirectional delivery body 415A has at least one network ofchannels 532; eachbidirectional delivery body 415B has at least two networks ofchannels 532. In the current embodiment,bidirectional delivery body 415B is manufactured from a solid block, and primary, secondary, andtertiary channels bidirectional delivery body 415B, and to direct the flow of molding material, a plurality of plugs, such asplug 554, which are inserted in to the bores that define respective primary, secondary, andtertiary channels - As shown in
FIG. 4 , and also inFIG. 11 , in the currentembodiment tip assembly 430 further includes adiverter block 451 secured tobottom surface 450 ofbidirectional delivery body 415B.Diverter block 451 has achannel 452 extending therethrough that reorients the flow of molding material through a 90° rotation from the bottom of bidirectional delivery body 515B to tip body channel 438. In the current embodiment, awedge 453 is also secured tobottom surface 450 ofbidirectional delivery body 415B which bears against opposite facingtip assemblies 430. Specifically,wedge 452 bears against opposing diverter blocks 450 (diverter block 450 associated with the left side ofbidirectional delivery body 415B anddiverter body 450 associated with the right side ofbidirectional delivery body 415B) to maintain a fluid seal betweendiverter block channel 452 and tip body channel 438. - It should be understood that in order to feed molding material to the four
mold cavities 408 on the right side ofbidirectional delivery body 415B, moldingmaterial entering inlet 431B and flows through a network of bi-molding material channels that are oriented 180 degrees to the network of bi-molding material channels 432 associated withinlet 431A. - It should also be understood that
unidirectional delivery bodies 415 have a channel arrangement similar to the channel arrangement in fluid communication with one ofinlets unidirectional delivery body 414 positioned outside the first column F of the array, to feed molding material to themold cavities 408 on the right side ofunidirectional delivery body 415A, molding material enters an inlet positioned similar onunidirectional delivery body 415A toinlet 431B ofbidirectional delivery body 415B and flows through the network of uni-molding material channels to tipassemblies 130 in fluid communication withgates 109A on the right side ofrespective mold cavities 408 in the first column F of the array. Referring tounidirectional delivery body 414 positioned outside the first column L of the array, to feed molding material to the fourmold cavities 408 on the left side ofunidirectional delivery body 415A, molding material enters an inlet positioned similar onunidirectional delivery body 415A toinlet 431B ofbidirectional delivery body 415B and flows through the network of uni-molding material channels to tipassemblies 130 in fluid communication withgates 109B on the left side ofrespective mold cavities 408 in the last column L of the array. - The aforementioned molding material channel configuration is as follows: 1
primary channel 532A×2secondary channels 532W, 532B″×2tertiary channels 532C′, 532C″ (one per eachsecondary channel 532B′, 532B″)=4 delivery body outlets 549 (seeFIG. 4A ), with eachoutlet 549 in fluid communication with a respective cavity 508.FIG. 5F is a perspective view ofbidirectional delivery body 415B ofFIG. 4 depicting fourtip assemblies 430 positioned on the right side ofbidirectional delivery body 415B and twotransfer bodies 414, one coupled to eachinlet - Referring to
FIGS. 5A-F a center plug, or plug 556 is provided inbidirectional delivery body 415B to facilitate placement of twoinlets centerline 447 ofdelivery body 415B rather than back to back or placement of eachinlet adjacent mold cavities 108 as shown inFIG. 3 . Referring also toFIG. 6 which is a perspective view ofplug 556 depicted inFIGS. 5A-D withFIG. 6A being a section A-A throughFIG. 6 .Plug 556 has acylindrical body portion 557 that is received in acorresponding bore 558 inbidirectional delivery body 415B. A locatingflange 559 extends frombody portion 557 to mate with a corresponding feature in a mold plate, (such asmold plate 102 shown inFIG. 1 ) to assist in positioningbidirectional delivery body 415B.Plug 556 defines ajunction 662 between each primarymolding material channel 532A and the pair of secondarymolding material channels 5323, 532B″ extending from a downstream end of each primarymolding material channel 532A.Junction 662 includes afirst interconnecting channel 664A, asecond interconnecting channel 664B, a first segment ofprimary channel 665A, a second segment ofprimary channel 665B, a first segment ofsecondary channel 667A, and a second segment of secondary channel 667B, first segment ofprimary channel 665A forming a portion of theprimary channel 532A of the one of the networks ofchannels 532, first segment ofsecondary channel 667A forming a portion ofsecondary channel 532B, of the other of the networks ofchannels 532, first interconnectingchannel 664A interconnecting first segment ofprimary channel 665A with first segment ofsecondary channel 667A, second segment ofprimary channel 665B forming a portion of theprimary channel 532A of the other of the networks ofchannels 532, second segment of secondary channel 667B forming a portion ofsecondary channel 532B of the other of the networks ofchannels 532, second interconnectingchannel 664B interconnecting second segment ofprimary channel 665B with second segment of secondary channel 667B. In the embodiment ofFIGS. 6 and 6A ,Plug 556 is a unitary or one piece plug manufactured by an additive manufacturing process such as laser sintering or the like. In an alternative embodiment, plug 556 may be manufactured from two halves that are brazed or otherwise integrally formed together, with one half ofplug 556 having the channel geometry shown inFIG. 6A and the other half or plug 556 having a corresponding mirrored geometry such that complete the peripheral boundary of the portion of primarymolding material channel 532A and secondarymolding material channels 532B′, 532B″ are formed inplug 556. That is, each half ofplug 556 includes a network of troughs such that when the two halves combined to formplug 556, the network of troughs defined the channels ofjunction 662. -
FIG. 7 is a perspective view of an alternative embodiment of a center plug, or plug 756 withFIG. 7A being a bottom view ofFIG. 7 . Features and aspects of the current embodiment can be used accordingly with the other embodiments. Plug 756 ofFIG. 7 is similar to plug 556 ofFIG. 6 , however, in the embodiment ofFIG. 7 plug 756 is a half plug having the channel geometry shown inFIG. 7A and bore 558 having a corresponding mirrored geometry such that bore in the delivery body completes the peripheral boundary of the portion of primarymolding material channel 532A and secondarymolding material channels 532B′, 532B″ are formed whenplug 756 is installed inbore 558. That is, plug 756 includes a network oftroughs 769 such that whenplug 756 is installed inbore 558, the network oftroughs 769 combines with a corresponding network of troughs (not shown) ofbore 558 to define the channels ofjunction 662. - In each of the embodiments of
FIGS. 6 and 7 plug Further plug -
FIG. 8 is a top view of an eight cavity edge-gated injection molding apparatus in accordance with an embodiment hereof, generally indicated byreference numeral 800, in whichbidirectional delivery bodies 415B are also used as unidirectional delivery bodies. Features and aspects of the current embodiment can be used accordingly with the other embodiments.FIG. 8A is a section view ofFIG. 8 taken along line A-A.FIG. 8B is a perspective view of a portion ofinjection molding apparatus 800 shown with cavity inserts 803 and support inserts removed.FIG. 8C is the perspective view ofFIG. 8B shown withmanifold 813 andinlet 812 removed.FIG. 8D is a perspective view ofbidirectional delivery body 415B and associated cavity inserts 803. - For discussion purposes, in the
current embodiment cavities 808 of edge-gatedinjection molding apparatus 800 are laid out in a two by four array, that is, an array having two columns and four rows, with the fourcavities 808 on the left (as viewed on page) being the first column F of the array and the fourcavities 808 on the right (as viewed on page) being the second or last column L of the array. In this array,cavity 808 of a respective row in the first column F andcavity 108 of the same respective row in the last column L are considered to be adjacent to each another. - As mentioned above
bidirectional delivery bodies 415B are also used asunidirectional delivery bodies 415 will be referred to as unidirectional delivery body/bodies 415C.Unidirectional delivery body 415C can have the same structure asbidirectional delivery body 415B as discussed having regard to the embodiment ofFIG. 4 . However, whenbidirectional delivery body 415B is used asunidirectional delivery body 415C, rather than deliver molding material to both ofinlets unidirectional delivery body 415C ofFIG. 8 is fed molding material via arespective transfer body 414 to one ofinlets - Specifically, referring to
FIG. 8A andFIG. 8C , and tounidirectional delivery body 415C positioned outside the first column F of the array, to feed molding material to themold cavities 808 on the right side ofunidirectional delivery body 415C, molding material entersinlet 431B and flows through the network of molding material channels (similar tochannels 532 ofFIG. 5A toFIG. 5E ) to tipassemblies 430 in fluid communication withrespective gates 809A on the left side ofmold cavities 808 in the first column F of the array. Referring tounidirectional delivery body 415C positioned outside the last column L of the array, to feed molding material to the fourmold cavities 408 on the left side ofunidirectional delivery body 415C, molding material entersinlet 431A and flows through the network of molding material channels (opposite tochannels 532 ofFIG. 5A toFIG. 5E ) to tipassemblies 430 in fluid communication withrespective gates 809B on the right side ofrespective mold cavities 808 in the last column L of the array. - Similar to the previous embodiments, each
cavity insert 803 is provided with twogates respective gates 809B ofcavities 808 in the first column F of the array and torespective gates 809A ofcavities 808 in the last column L of the array,bidirectional delivery body 415B is positioned betweencavities 808 in the first column F of the array andcavities 808 in the last column L of the array. Referring toFIG. 8C andFIG. 8D ,bidirectional delivery body 415B has twoinlets mold cavities 808 on the left side ofbidirectional delivery body 415B, molding material entersinlet 431A and flows through the network of molding material channels (similar tochannels 532 ofFIG. 5A toFIG. 5E ) to tipassemblies 430 in fluid communication withrespective gates 809B on the right side ofmold cavities 808 in the first column F of the array, and to feed molding material to the fourmold cavities 808 on the right side ofbidirectional delivery body 415B, molding material entersinlet 431B and flows through the network of molding material channels (opposite tochannels 532 ofFIG. 5A toFIG. 5E ) to tipassemblies 430 in fluid communication withrespective gates 809A on the right side ofrespective mold cavities 808 in the last column L of the array. - In the current embodiment,
manifold 813 receives a stream of molding material viainlet 812 and divides it evenly between four outlets (not shown inFIG. 8 andFIG. 8A toFIG. 8D ), with one outlet being in fluid communication withinlet 431B of unidirectional delivery body 425C positioned outside the first column F of the array, one outlet being in fluid communication withinlet 431A of unidirectional delivery body 425C positioned outside the last column L column of the array and the remaining two outlets in fluid communication withrespective inlets bidirectional delivery body 415B. Accordingly, in this arrangement eachcavity 808 receives a stream of molding material from twodelivery bodies 415; one stream from abidirectional delivery body 415B and the other from a unidirectional delivery body 815C. - Referring to
FIG. 8 ,FIG. 8A , andFIG. 8C ,injection molding apparatus 800 includes support inserts 860. Specifically, one column of four support inserts 860 is positioned relative tounidirectional delivery body 415C that is outside of the first column F of the array, and another column of four support inserts is positioned relative tounidirectional delivery body 415C that is outside of the last column L of the array. In the current embodiment, the pitch spacing of support inserts 860 is equal to that of cavity inserts 803. Support inserts 860 have an outer profile similar to that of cavity inserts 803 and would be received in a corresponding bore in a mold plate, such asmold plate 102 shown inFIG. 1 , and also include also include respective first sealing surface 838 and circumferential sealing surface 839. Support inserts 860 are used as place holders to enable the use ofbidirectional delivery bodies 415, asunidirectional delivery bodies 415C. In an embodiment (not shown) support inserts 860 are made from the same material as cavity inserts 803, and also have the same internal geometry as cavity inserts 803 thus allowing arespective support insert 860 to be used as aspare cavity insert 803 in the event that acavity insert 803 becomes damaged. - Referring to
FIG. 8A andunidirectional delivery body 415C positioned outside the first column of the array,wedge 453 bears against opposite facingtip assemblies 430;tip assembly 430 on the left side ofunidirectional delivery body 415C applies force againstsupport insert 860, whereastip assembly 430 on the right side of applies force againstcavity insert 803 such thatunidirectional delivery body 415C is held in place between cavity inserts 803 in the first column of the array andsupport insert 860 by opposite facingtip assemblies 430. In the currentembodiment tip assembly 430 associated withsupport insert 860 has ablank tip body 861, that isblank tip body 861 does not have a melt channel extending therethrough. - In each of the above examples the specific delivery body and
tip assembly 130 arrangement is shown by way of example and not limitation. Further non-limiting examples of tip and delivery body arrangements can be found in the following examples, U.S. Pat. No. 4,981,431, which is incorporated by reference herein, depicts a one piece tip that is threadably coupled to an edge gating nozzle body that creates face seal with acorresponding cavity insert 103. In this arrangement the tip can be said to be fixed to a delivery body and slidable relative to a corresponding cavity insert. In another embodiment tip assembly is a two piece injection tip that is threadably retained to delivery body by way of a separate transfer seal, such an arrangement can be found in U.S. Pat. No. 7,179,081 also incorporated by reference herein. In this arrangement the tip can be considered fixed to the delivery body by way of a transfer seal, and is also fixed to cavity insert 103 by way of the circumferential engagement between transfer seal sealing diameter and cavity insert bore. In still a further embodiment a tip seal arrangement such as depicted in U.S. Pat. No. 7,794,228 which is incorporated herein by reference, can also be used in embodiments hereof without diverting from the scope of the disclosure. Whiletip assemblies 130 are shown projecting at a 90° angle to theaxial centerline 110 of eachcavity 108, tip assemblies may also project at an angle to axial centerline in embodiments where it can be disadvantageous to inject molding material directly at the mold core. - The use of the terms rows and columns throughout this disclosure is not intended to limit the scope of the disclosure, but is meant to convey the relationship between the positions and orientations of the delivery bodies and cavities.
- While various embodiments according to the present disclosure have been described above, it should be understood that they have been presented by way of illustration and example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the disclosure. For example, where suitable, an apparatus can use a combination of combined
delivery body transfer body 114 connected tobidirectional delivery body 115B orunidirectional delivery body 115A. As another example, where suitable, combineddelivery body transfer body 114 connected tobidirectional delivery body 115B orunidirectional delivery body 115A, or vice versa. As another example, the rows and columns do not necessarily have to be horizontal or vertical. As another example, the term array also includes a sub-array of a larger array. For example, an injection molding apparatus may have 96 cavities laid out in an eight by twelve array (eight columns and twelve rows) which is made up of six sub arrays, each sub array having 16 cavities arranged in four columns by four rows of cavities or other suitable combination of sub arrays. Thus, the breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the appended claims and their equivalents. It will also be understood that each feature of each embodiment discussed herein, and of each reference cited herein, can be used in combination with the features of any other embodiment. All patents and publications discussed herein are incorporated by reference herein in their entirety.
Claims (5)
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US16/152,124 US20190099932A1 (en) | 2012-08-28 | 2018-10-04 | Edge-gated injection molding apparatus |
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US201261693876P | 2012-08-28 | 2012-08-28 | |
PCT/CA2013/000745 WO2014032165A1 (en) | 2012-08-28 | 2013-08-28 | Edge-gated injection molding apparatus |
US201514424697A | 2015-02-27 | 2015-02-27 | |
US14/986,205 US10093054B2 (en) | 2012-08-28 | 2015-12-31 | Edge-gated injection molding apparatus |
US16/152,124 US20190099932A1 (en) | 2012-08-28 | 2018-10-04 | Edge-gated injection molding apparatus |
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US14/986,205 Continuation US10093054B2 (en) | 2012-08-28 | 2015-12-31 | Edge-gated injection molding apparatus |
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US16/152,124 Abandoned US20190099932A1 (en) | 2012-08-28 | 2018-10-04 | Edge-gated injection molding apparatus |
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US14/986,205 Active 2033-11-12 US10093054B2 (en) | 2012-08-28 | 2015-12-31 | Edge-gated injection molding apparatus |
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EP (1) | EP2890543B1 (en) |
CN (1) | CN104736314B (en) |
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US11084195B2 (en) * | 2016-05-27 | 2021-08-10 | Husky Injection Molding Systems Ltd. | Mold gate structures |
US10471542B1 (en) * | 2017-06-27 | 2019-11-12 | United States Of America As Represented By The Administrator Of Nasa | Cladding and freeform deposition for coolant channel closeout |
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IT201700105306A1 (en) * | 2017-09-20 | 2019-03-20 | Inglass Spa | PROCEDURE AND EQUIPMENT FOR THE PRODUCTION OF ITEMS INJECTION MOLDED PLASTIC CABLES |
CN109049540A (en) * | 2018-08-22 | 2018-12-21 | 珠海格力精密模具有限公司 | Injection mould |
CN112157864B (en) * | 2020-09-16 | 2022-06-24 | 扬州市职业大学(扬州市广播电视大学) | Rubber injection molding machine and molding method |
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Also Published As
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CN104736314B (en) | 2017-04-26 |
PT2890543T (en) | 2019-06-11 |
CN104736314A (en) | 2015-06-24 |
US20150202811A1 (en) | 2015-07-23 |
PL2890543T3 (en) | 2019-08-30 |
EP2890543A1 (en) | 2015-07-08 |
US9227351B2 (en) | 2016-01-05 |
WO2014032165A1 (en) | 2014-03-06 |
EP2890543B1 (en) | 2019-03-06 |
US20160114506A1 (en) | 2016-04-28 |
EP2890543A4 (en) | 2016-04-20 |
US10093054B2 (en) | 2018-10-09 |
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