Hot Runner Nozzle Connection Device for Reliable Electrical Contact
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Solution Overview
Problem
Existing hot runner nozzles face challenges with unreliable electrical connections due to surface cleanliness, clamping force variability, and increased installation complexity, leading to power losses and potential damage from excessive heat at connection points.
Innovation Solution
A connection device with an insulating body arranged in a receiving sleeve, featuring feet that attach to the heating element for mechanical stability and a secure, force-fitting connection, ensuring reliable contact and mechanical strain relief, while allowing for easy installation and removal of the hot runner nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a detachable plug-in connection is used between heating coil contact pins and connecting cable plug contacts, then the hot runner nozzle can be installed and removed easily, but the electrical connection reliability deteriorates due to surface cleanliness issues and clamping force variability
Solution Approach 1:
The patent introduces an intermediary connection structure where the connecting cable is secured in the receiving sleeve through a force-fitting connection. This intermediary mechanism mediates between the detachable plug-in requirement and the reliability requirement by providing a stable mechanical and electrical connection path that is less sensitive to surface conditions and clamping force variations.
Solution Approach 2:
The connection system is segmented into distinct components: the heating element with connection contacts, the insulating body, the receiving sleeve, and the connecting cable with contact elements. This segmentation allows each component to be optimized independently - the force-fitting connection in the receiving sleeve ensures reliability while the overall modular design maintains ease of installation and removal.
2Reliability
If conventional connection methods with insulating bushings and clamping rings are used, then electrical connection can be established, but the device complexity increases and installation becomes more difficult
Solution Approach 1:
The patent merges multiple functions into the receiving sleeve component: it provides electrical insulation, secures the connecting cable through force-fitting, positions the contact elements, and relieves mechanical strain. This consolidation eliminates the need for separate insulating bushings, clamping rings, and positioning elements, thereby reducing device complexity while maintaining reliable electrical connection.
Solution Approach 2:
The receiving sleeve is designed as a multi-functional component that simultaneously performs insulation, mechanical retention, electrical connection, and strain relief functions. This universal design simplifies the overall connection device structure by replacing multiple specialized components with a single versatile element.
3Reliability
If the electrical connection is made with traditional clamping methods, then electrical contact can be established, but power losses occur and excessive heat can damage components
Solution Approach 1:
The force-fitting connection in the receiving sleeve acts as an intermediary that provides a stable, low-resistance electrical path between the heating element and connecting cable. This intermediary connection reduces contact resistance and prevents excessive heat generation, thereby minimizing power losses while maintaining reliable electrical contact.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a reliable, temperature-resistant, and mechanically robust electrical connection that prevents power losses and damage, simplifies installation, and reduces maintenance costs by ensuring consistent contact and easy handling of the connecting cable.
Implementation Method 1
an electrical conductor, which generates heat when an electrical voltage is applied or when electrical current flows through
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
In a hot runner nozzle (1) with an electric heating element (10) comprising a connection device (30) for generating an electrical connection to a connecting cable (40), wherein connecting contacts (22, 23) of the heating element terminate in an insulating body (50) of the connecting device (30) which electrically separates the connecting contacts (22, 23) from each other, and wherein the connecting cable has contact elements (41, 42) that can be electrically contacted with the connecting contacts of the heating element, it is provided that the insulating body (50) is arranged at least partially in a receiving sleeve (70) of the connecting device (30), such that the connecting cable (40) can be fixed in or on the receiving sleeve (30) in such a way that the contact elements of the connecting cable electrically contact the connecting contacts of the heating element.and that a first end (71) of the receiving sleeve (70) pointing towards the heating element surrounds the insulating body (50) and has two opposite outwardly pointing feet (81, 82) at this first end (71) that are attached to the heating element.