Hinged Hot Runner Manifold for Injection Molding
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Solution Overview
Problem
Existing hot runner systems in injection molding face challenges in maintaining uninterrupted melt flow between moving mold portions, leading to leakage and complexity, especially when producing larger containers with thin walls or featuring external ribs, as prior solutions often result in overly complex arrangements or require valves that are prone to leakage.
Innovation Solution
A hinged hot runner manifold assembly that allows for the movement of hot runner nozzles relative to stationary portions using hinged joints, ensuring continuous melt flow and minimizing leakage by allowing rotational movement while maintaining a sealed connection through socket and bushing combinations and clamping mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If additional hot runner nozzles are positioned at side portions of the mold to expand beyond size restrictions, then the ability to produce larger containers is improved, but the complexity of the mold system increases significantly
Solution Approach 1:
The hot runner manifold is divided into multiple separate manifolds, each serving specific mold portions. This segmentation allows independent positioning and simplifies the overall system architecture, enabling larger container production without proportionally increasing overall system complexity.
Solution Approach 2:
The invention introduces movable manifolds that can change position relative to the mold portions. This dynamic capability allows the hot runner system to adapt to different mold configurations and container sizes, eliminating the need for permanently complex fixed arrangements.
2Length of stationary object
If hot runner nozzles are positioned at side portions of the mold to reach distant areas, then melt injection capability is improved, but leakage problems increase due to movement between mold portions
Solution Approach 1:
The movable manifolds are designed to move with their associated mold portions while maintaining continuous, sealed connections. This dynamic sealing capability ensures reliable melt flow even when mold portions move relative to each other, eliminating leakage problems associated with fixed positioning.
Solution Approach 2:
The movable manifolds act as intermediaries between the stationary hot runner nozzles and the moving mold portions. They absorb and accommodate the relative movements while maintaining continuous melt flow paths, preventing leakage at the interface between moving and stationary components.
3Reliability
If valves are introduced between interfaces to prevent leakage, then melt flow sealing is improved, but the complexity and proneness to leakage increases
Solution Approach 1:
The invention extracts and eliminates the need for valves at the interfaces between movable and stationary manifolds. By designing the movable manifolds to maintain sealed connections through their movement capability, the harmful element (valves) is removed entirely, simplifying the system while maintaining reliability.
4Reliability
If melt flow is stopped when mold portions are in motion, then leakage is prevented, but productivity decreases
Solution Approach 1:
The movable manifolds enable continuous melt flow during mold portion movement by dynamically adjusting their position to maintain sealed connections. This eliminates the need to stop melt flow during molding operations, maintaining high productivity while preventing leakage.
Solution Approach 2:
The invention ensures continuous melt flow through the movable manifolds even when mold portions are in motion. The manifolds maintain unbroken melt pathways throughout the molding cycle, allowing useful action (melt injection) to continue without interruption, thereby maximizing productivity.
Data Source
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AI summary
A melt distribution manifold for use with first and second mold portions moveable with respect to each other, the melt distribution manifold including a melt inlet means for receiving melt from an injection molding machine, a first manifold portion connected to the first mold portion, wherein the first manifold portion is stationary with respect to the first mold portion, a second manifold portion connecting the first manifold portion to the hot runner nozzle, wherein the second manifold portion is moveable with respect to the first manifold portion such that when the first mold portion moves with respect to the second mold portion, the second manifold portion remains connected to the first manifold portion and to the hot runner nozzle, a hinged joint connecting the first manifold portion to the second manifold portion. Each of the first manifold portion, the second manifold portion, and the hinged joint having respective melt distribution bores in fluid communication with each other.