A nozzle with melt leakage detection

Abstract

The application relates to the technical field of melt conveying, in particular to a nozzle with a melt leakage detection function. The nozzle comprises a nozzle body, a detection rod, an elastic member and a detection switch. The detection rod is arranged on the nozzle body in an axially movable manner, and an inductive end of the detection rod abuts against an outlet peripheral area of a melt flow channel in an initial position; the elastic member provides an elastic force for the detection rod to keep the initial position; and a trigger part of the detection switch corresponds to the position of a driving end of the detection rod. When melt leakage occurs in the outlet area, the leaked melt pushes the inductive end of the detection rod to move axially against the elastic force, and then triggers the detection switch through the driving end to send a signal. The scheme directly integrates the detection mechanism in the nozzle body, is compact in structure, realizes real-time, direct and reliable detection of leakage, and effectively improves the safety and economy of injection molding production.

Description

Technical Field

[0001] This application relates to the field of melt conveying technology, and in particular to a nozzle with melt leakage detection function. Background Technology

[0002] In the processing of polymer materials such as injection molding and extrusion, the nozzle is a key component connecting the melt delivery device and the mold. The reliability of the seal at the interface between the nozzle and the mold directly affects production safety and efficiency. Due to installation, wear, or process fluctuations, high-temperature melt leakage is prone to occur at this connection, which not only causes waste of raw materials and equipment damage, but also poses a significant risk of causing safety accidents such as burns and fires.

[0003] Currently, monitoring of nozzle leaks mainly relies on manual inspections or external sensors. The former cannot provide real-time early warnings; the latter, because it is not directly integrated into the leak point, suffers from response lag and insensitive detection, and the system is complex and costly.

[0004] Therefore, there is an urgent need for a direct leak detection solution that can be tightly integrated with the nozzle, has a simple structure, and responds promptly. Utility Model Content

[0005] To address one or more of the above-mentioned technical problems, this application provides a nozzle with melt leakage detection function, comprising a nozzle body having a melt flow channel, and the nozzle with melt leakage detection function further comprising: A detection rod is axially movable on the nozzle body, and the detection rod includes a sensing end and a driving end, wherein the sensing end is configured to abut against the outer periphery of the outlet of the melt flow channel in the initial position; An elastic element acts on the detection rod to provide an elastic force to the detection rod to maintain its initial position; A detection switch is fixedly mounted on the nozzle body, and its trigger part corresponds to the position of the drive end of the detection rod; The detection rod is configured to move axially from the initial position to the trigger portion of the detection switch, driven by the leaking melt, causing the drive end to actuate the detection switch.

[0006] The nozzle with melt leakage detection function provided in this application also includes a nozzle head, which is movably connected to the nozzle body, and the outer periphery of the outlet of the melt flow channel is located at the junction of the nozzle head and the nozzle body.

[0007] According to the nozzle with melt leakage detection function provided in this application, the nozzle body is provided with a mounting hole, the mounting hole extends along the melt flow channel direction, and the detection rod is axially movable and accommodated in the mounting hole.

[0008] According to the nozzle with melt leakage detection function provided in this application, a flow gap is formed at the joint between the nozzle head and the nozzle body, and the flow gap communicates with the orifice of the mounting hole. In the initial position, the sensing end of the detection rod is blocked by the elastic element, thus obstructing the external leakage path of the flow gap.

[0009] According to the nozzle with melt leakage detection function provided in this application, the elastic element is one of a helical spring, a disc spring, or a spring sheet.

[0010] According to the nozzle with melt leakage detection function provided in this application, the detection switch is one of a micro switch, a proximity switch or a Hall switch.

[0011] The above-mentioned one or more technical solutions provided in this application include at least the following technical effects: The primary benefit of this nozzle with melt leakage detection is its real-time, accurate detection and rapid response to melt leaks, effectively addressing the core pain points of existing technologies, such as the reliance on slow manual inspections and the insensitivity of external sensors. Its detection component is directly integrated into the nozzle body. The sensing end of the detection rod precisely contacts the outer area of ​​the flow channel outlet, where the highest risk of melt leakage exists. Leaking melt immediately contacts the sensing end and drives the detection rod, rapidly actuating the detection switch via mechanical triggering. This promptly outputs an alarm or shutdown signal, preventing the leakage from escalating at its source. This significantly reduces the probability of burns, fires, and other safety accidents caused by high-temperature melt leakage, while also avoiding continuous waste of raw materials and additional damage to critical equipment components, greatly improving the safety and economy of injection molding production.

[0012] Secondly, the technical solution features a simple and reliable structural design, balancing low cost and ease of implementation, and possesses outstanding practical value. The entire detection system consists only of a detection rod, an elastic element, and a detection switch as its core components, without complex circuits or control systems. This reduces processing and assembly difficulty, significantly lowering manufacturing costs and the likelihood of malfunctions compared to traditional external detection equipment. Simultaneously, the cooperative design of the detection rod and elastic element creates a "pre-blocking" effect. In the initial state, the sensing end blocks the external leakage path of the flow gap. Even if a minute leakage occurs, it accumulates within the gap before triggering detection, improving detection sensitivity and minimizing the amount of leaked melt overflowing. This achieves the dual functions of "detection" and "preliminary blocking," further optimizing the performance.

[0013] Finally, the nozzle's detachable structure and diverse component selection design give it excellent adaptability and ease of maintenance. The nozzle body and nozzle head are detachably connected. When the nozzle head needs replacement due to long-term wear or to adapt to different molds, there is no need to disassemble the entire nozzle or stop the machine for maintenance; only the nozzle head needs to be disassembled and reassembled. This significantly shortens maintenance time, reduces maintenance costs, and ensures production continuity. The elastic element can be selected from helical springs, disc springs, or sheet springs depending on the installation space and melt pressure characteristics. The detection switch can be selected from micro switches, proximity switches, or Hall switches according to operating conditions. This allows for flexible adaptation to different specifications of injection molding equipment, melt types, and production environments with varying degrees of harshness, effectively broadening the nozzle's application scenarios and meeting diverse production needs. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the structure of a nozzle with melt leakage detection function provided in some embodiments of this application.

[0016] Figure label: 1. Nozzle body; 2. Melt flow channel; 3. Detection rod; 31. Sensing end; 32. Drive end; 33. Mounting hole; 4. Elastic element; 5. Detection switch; 6. Nozzle head; 7. Flow gap. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0018] The terms "first" and "second" in the specification and claims of this application may explicitly or implicitly include one or more of the features. In the description of this application, unless otherwise stated, "multiple" means two or more. Furthermore, "and / or" in the specification and claims indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0019] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0020] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0021] See Figure 1 The nozzle with melt leakage detection function provided in this application is based on the real-time perception and trigger response of melt leakage by integrating detection components, which effectively solves the problem of existing nozzles lacking leakage detection capability. The structure, component connection relationship and working process of the nozzle are described in detail below with reference to specific embodiments.

[0022] The nozzle includes a nozzle body 1, which serves as the basic supporting component of the entire nozzle. A melt flow channel 2 is provided inside the nozzle body 1. The melt flow channel 2 is used to transport high-temperature melt during the injection molding process, ensuring that the melt can be smoothly guided from the injection molding machine barrel to the area that subsequently mates with the mold. At the same time, the nozzle body 1 also provides a stable mounting reference for other components, ensuring the relative positional accuracy of each component and laying a structural foundation for the reliable realization of the leakage detection function.

[0023] A detection rod 3 is also provided on the nozzle body 1. The detection rod 3 has a rod-shaped structure and is divided into two functional sections along its length: a sensing end 31 and a driving end 32. A mounting hole 33 adapted to the detection rod 3 is provided on the nozzle body 1. The detection rod 3 is axially movable and mounted on the nozzle body 1 through this mounting hole 33. The extension direction of the mounting hole 33 is consistent with the axial direction of the detection rod 3, ensuring that the detection rod 3 will not deviate or get stuck during movement. Initially, the sensing end 31 of the detection rod 3 abuts against the outer periphery of the melt flow channel 2. This area is the key part where the melt exits from the melt flow channel 2 and engages with the mold inlet. It is also the area most prone to melt leakage due to sealing failure during actual injection molding. Placing the sensing end 31 here allows it to contact the leaking melt immediately, ensuring timely leak detection.

[0024] To ensure that the detection rod 3 can stably maintain its initial position when there is no melt leakage, the nozzle also includes an elastic element 4. The elastic element 4 acts between the detection rod 3 and the nozzle body 1. Specifically, it can be set between the drive end 32 side of the detection rod 3 and the end of the mounting hole 33, or it can be sleeved on the outside of the detection rod 3 and abut against the sensing end 31 and the inner wall of the mounting hole. In its natural state, the elastic element 4 applies an axial elastic force to the detection rod 3 toward the sensing end 31. This elastic force can tightly abut the sensing end 31 of the detection rod 3 against the outer periphery of the melt flow channel 2 outlet area, preventing the sensing end 31 from detaching from the target area due to loosening of the detection rod 3. This ensures that when melt leakage occurs, the leaking melt can directly act on the sensing end 31 and push the detection rod 3 to move. At the same time, the magnitude of the elastic force of the elastic element 4 can be adapted according to the pressure characteristics of the melt during the actual injection molding process, ensuring that the detection rod 3 will not be accidentally triggered by a small external force, and can be smoothly pushed when melt leakage occurs, thus balancing the reliability and sensitivity of the detection.

[0025] In addition, a detection switch 5 is fixedly installed on the nozzle body 1. The detection switch 5 can be fixed by a conventional mechanical connection, such as by bolt fastening or snap-fit ​​structure to the outer wall of the nozzle body 1. The trigger part of the detection switch 5 and the drive end 32 of the detection rod 3 are axially aligned, that is, when the detection rod moves axially, its drive end 32 can directly contact and act on the trigger part of the detection switch 5. The detection switch 5 remains in its initial state when not triggered. Once actuated by the drive end 32, it can output a corresponding electrical signal. This signal can be further transmitted to the control system of the injection molding equipment to realize functions such as equipment shutdown or alarm prompt, thereby timely stopping the continued development of leakage.

[0026] The nozzle operates as follows: Under normal injection molding conditions without melt leakage, the elastic force applied by the elastic element 4 keeps the detection rod 3 in its initial position. The sensing end 31 abuts against the outer area of ​​the melt flow channel 2 outlet, and the driving end 32 maintains a certain distance from the trigger part of the detection switch 5, with the detection switch 5 in an untriggered state. When melt leakage occurs in the outer area of ​​the melt flow channel outlet, the leaking high-temperature melt will directly contact the sensing end 31 of the detection rod 3 and apply a thrust along the axial direction of the detection rod 3 to the sensing end 31. After overcoming the elastic force of the elastic element 4, this thrust drives the detection rod 3 as a whole to move along the axial direction of the mounting hole toward the driving end 32. As the detection rod 3 moves, its driving end 32 gradually approaches the trigger part of the detection switch 5 until it contacts and actuates the trigger part. At this time, the detection switch 5 is triggered and outputs a signal, which can trigger the equipment to stop or alarm, thereby realizing real-time detection and emergency handling of melt leakage, effectively avoiding safety accidents, raw material waste, and equipment damage.

[0027] In some embodiments, to facilitate the maintenance and replacement of easily worn parts and to adapt to different specifications of injection molds to improve the versatility of the nozzle, the nozzle body 1 is equipped with a nozzle head 6 via a detachable connection. Specifically, the nozzle head 6 can be assembled and fixed to the nozzle body 1 through conventional mechanical connection structures such as threaded engagement, snap-fit, or flange connection. The advantage of this detachable design is that when the nozzle head 6 wears or deforms due to long-term contact with the mold inlet, or when it is necessary to replace the nozzle head 6 with a suitable structure according to the type of melt used in injection molding, it is not necessary to disassemble or replace the entire nozzle body 1; only the nozzle head 6 needs to be disassembled and installed separately. This significantly reduces the maintenance cost of the equipment, shortens the downtime for maintenance, and ensures the continuity of injection molding production.

[0028] Specifically, the outer perimeter of the melt flow channel 2 is located at the junction of the nozzle head 6 and the nozzle body 1. As the mating surface of two independent components, this junction must withstand the scouring of high-temperature melt and the pressure of the mold during the injection molding process. It is prone to melt leakage due to changes in the flow gap, aging of seals, or deviations in assembly precision. Therefore, this area is set as the core area for melt leakage detection, which can accurately cover the part with the highest leakage risk. This provides a structural basis for the detection rod 3 to achieve efficient and timely leakage detection, and further improves the pertinence and reliability of the entire detection function.

[0029] To ensure that leaking melt is directed to the detection rod 3 and prevents it from spreading randomly at the joint, thus affecting the detection response speed, a flow gap 7 is formed at the joint between the nozzle head 6 and the nozzle body 1 to guide the drive end 31 of the detection rod 3. This flow gap 7 extends in the same direction as the axial direction of the detection rod 3, and one end of the flow gap 7 is directly connected to the opening of the mounting hole 33. This structural design allows the leaking melt to flow smoothly into the mounting hole 33 along this functional flow gap, directly contacting the sensing end 31 of the detection rod 3. This effectively avoids the problem of the sensing end 31 failing to detect the leak in time due to melt diffusion, while also reducing environmental pollution and safety threats to operators.

[0030] Specifically, when the detection rod 3 is in the initial position, under the elastic force applied by the elastic element 4, the sensing end 31 of the detection rod 3 will fit tightly against the opening of the flow gap, thereby directly blocking the external leakage path of the flow gap. This design not only ensures that the detection rod 3 remains stably in its initial position when there is no melt leakage through elastic force, preventing the sensing end 31 from detaching from the flow gap opening due to loosening of the detection rod 3 and affecting the detection sensitivity, but also achieves the additional technical effect of "pre-blocking"—even if a small melt leak occurs at the junction of the nozzle head 6 and the nozzle body 1, the leaked melt cannot directly overflow through the flow gap, but will accumulate in the flow gap and generate a continuous thrust on the sensing end 31; when the thrust gradually increases to be sufficient to overcome the elastic force of the elastic element 4, the detection rod 3 will be pushed to move axially along the mounting hole 33. This "block first, then detect" structural logic not only improves the sensitivity of leak detection, but also minimizes the amount of melt leakage before the detection is triggered, further reducing the probability of safety accidents and the waste of raw materials.

[0031] In some embodiments, the elastic element 4 serves as a component that provides initial position holding force to the detection rod 3. Its type can be selected based on the installation space of the nozzle body 1, the pressure characteristics of the melt under injection molding conditions, and the requirement for stability of the elastic force. Specifically, it can be one of a coil spring, a disc spring, or a spring sheet. When a coil spring is selected as the elastic element 4, its structure is simple and its processing cost is low. It can be directly sleeved on the outside of the detection rod 3, with one end abutting against the limiting step provided on the detection rod 3 and the other end abutting against the end of the installation channel 33. The compression deformation of the coil spring provides a continuous and stable elastic force. This assembly method not only facilitates later maintenance and replacement but also allows for flexible adaptation to different elastic force requirements by adjusting the wire diameter and number of turns of the coil spring, making it suitable for most conventional injection molding pressure conditions. If the axial space of the mounting channel 33 on the nozzle body 1 is limited, or if the thrust generated by melt leakage during injection molding is large, a disc spring can be selected as the elastic element 4. Disc springs have the characteristics of small axial size and strong load-bearing capacity. They can be installed individually or in combination in the mounting channel 33. They can provide a large elastic force with a small amount of compression, effectively preventing the detection rod 3 from moving erroneously due to excessive melt thrust. At the same time, they save installation space and are suitable for the structural design of miniaturized nozzles. When the overall size of the nozzle body 1 is small and there is not enough space in the mounting channel 33 to accommodate a helical spring or disc spring, a spring sheet can also be selected as the elastic element 4. The spring sheet is usually made of elastic metal material and can be directly fixed to the inner wall of the nozzle body 1 or the mounting channel 33 by bolts. One end of the spring sheet abuts against the driving end 32 or sensing end 31 of the detection rod 3. The elastic force is provided by the bending deformation of the spring sheet itself. This structure does not require additional installation space, which can simplify the overall structure of the detection component to the greatest extent and is suitable for miniature injection molding nozzles with strict space requirements.

[0032] In some embodiments, the detection switch 5 may be selected from a micro switch, a proximity switch, or a Hall switch. When a micro switch is selected as the detection switch 5, it has the characteristic of mechanical contact triggering. The trigger part is usually designed as a pressable spring structure. During installation, the micro switch is simply fixed to the nozzle body 1 with bolts, so that the trigger part corresponds to the drive end 32 of the detection rod 3 in the axial direction. When the detection rod 3 moves under the push of the leaking melt, the drive end 32 can directly contact and press the trigger part of the micro switch to realize rapid signal switching. This triggering method has a fast response and clear action, which is suitable for scenarios with high detection accuracy requirements and no excessive dust or high temperature interference in the injection molding environment. If the injection molding production line needs to operate continuously for a long time, and the service life requirement for the detection switch 5 is high, a proximity switch can be selected as the detection switch 5. The proximity switch does not need to be in direct contact with the drive end 32 of the detection rod 3. Only a metal sensing block needs to be set at the end of the drive end 32 of the detection rod 3. When the drive end 32 moves into the sensing range of the proximity switch, the proximity switch can be triggered by electromagnetic induction or capacitive induction. This non-contact triggering can avoid mechanical wear, significantly extend the service life of the detection switch 5, and reduce the frequency of later maintenance. In the case of high injection molding ambient temperature or a lot of melt dust, a Hall switch can also be selected as the detection switch 5. The Hall switch works based on the Hall effect. A magnetic component needs to be installed on the drive end 32 of the detection rod 3. When the drive end 32 moves the magnetic component to the sensing area of ​​the Hall switch, the Hall switch can output a trigger signal. It has strong resistance to high temperature and dust interference, and can work stably even in harsh injection molding environments, effectively avoiding false alarms or signal failures caused by environmental factors.

[0033] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A nozzle with melt leakage detection function, comprising a nozzle body having a melt flow channel, characterized in that, Also includes: A detection rod is axially movable on the nozzle body, and the detection rod includes a sensing end and a driving end, wherein the sensing end is configured to abut against the outer periphery of the outlet of the melt flow channel in the initial position; An elastic element acts on the detection rod to provide an elastic force to the detection rod to maintain its initial position; A detection switch is fixedly mounted on the nozzle body, and its trigger part corresponds to the position of the drive end of the detection rod; The detection rod is configured to move axially from the initial position to the trigger portion of the detection switch, driven by the leaking melt, causing the drive end to actuate the detection switch.

2. The nozzle with melt leakage detection function according to claim 1, characterized in that, It also includes a nozzle head, which is movably connected to the nozzle body, and the outer periphery of the melt flow channel outlet is located at the junction of the nozzle head and the nozzle body.

3. The nozzle with melt leakage detection function according to claim 2, characterized in that, The nozzle body is provided with a mounting hole that extends along the direction of the melt flow channel, and the detection rod is axially movable and accommodated in the mounting hole.

4. The nozzle with melt leakage detection function according to claim 3, characterized in that, A flow gap is formed at the junction of the nozzle head and the nozzle body, and the flow gap communicates with the orifice of the mounting hole. In the initial position, the sensing end of the detection rod is blocked by the elastic element, thus obstructing the external leakage path of the flow gap.

5. The nozzle with melt leakage detection function according to claim 1, characterized in that, The elastic element is one of a helical spring, a disc spring, or a spring sheet.

6. The nozzle with melt leakage detection function according to claim 1, characterized in that, The detection switch is one of a micro switch, a proximity switch, or a Hall switch.

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