Injection Molding Flow Divider for Uniform Shutter-Gated Filling
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Solution Overview
Problem
Existing injection molding apparatuses create non-uniform flow zones in front of and behind the shutter, leading to defects in molded products such as non-constant wall thickness in preforms and variations in thickness or perpendicularity in test tubes due to different flow speeds.
Innovation Solution
A component with a specific geometry that divides the molten plastic material flow into two portions before entering the injection channel, ensuring similar speed profiles in both zones by using a central part with bulkheads and lateral surfaces to guide the flow uniformly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a shutter is used to control material flow in the injection channel, then the communication between injection nozzle and molding cavity can be opened or closed, but non-uniform flow zones are created with different flow speeds in front of and behind the shutter
Solution Approach 1:
The injection channel is divided into multiple zones by the bulkheads, creating separate flow paths that guide material uniformly. The bulkheads segment the channel cross-section to ensure even distribution of molten material, preventing stagnation zones while maintaining shutter control functionality.
Solution Approach 2:
The bulkheads create different flow conditions in different zones of the injection channel. By strategically positioning bulkheads at specific locations, the patent optimizes flow distribution locally - ensuring uniform flow in critical zones while allowing the shutter to maintain its control function.
2Shape
If the outlet channel has an annular section due to the shutter presence, then the shutter can be positioned coaxially, but two zones with different flow speeds are created causing stagnation zones
Solution Approach 1:
The outlet channel is segmented by bulkheads that divide the flow into multiple streams. This segmentation prevents the formation of large stagnation zones by distributing material more evenly across the channel cross-section, while the annular geometry is preserved for shutter accommodation.
Solution Approach 2:
The bulkheads extend in the axial direction of the channel, adding a dimensional element that disrupts stagnant flow patterns. By introducing this axial structure, the patent transforms the flow dynamics from two-dimensional annular flow to a more complex three-dimensional pattern that eliminates dead zones.
3Reliability
If material flows through zones with different speeds behind and in front of the shutter, then the shutter mechanism functions, but defects are generated on molded parts with non-constant wall thickness
Solution Approach 1:
The bulkheads create optimized flow conditions in specific zones of the injection channel. By positioning bulkheads to accompany flow portions through critical sections, the patent ensures uniform material distribution reaches the gate zone, resulting in consistent wall thickness in molded parts while the shutter maintains its sealing function.
Solution Approach 2:
The bulkheads pre-condition the material flow before it reaches the shutter and gate zone. By distributing and equalizing flow speeds upstream, the patent prevents the formation of non-uniform material characteristics that would otherwise cause wall thickness variations in the final molded product.
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 achieves uniform material flow, reducing defects in molded products by ensuring consistent thickness and morphology, particularly in preforms and test tubes.
Implementation Method 1
dividing the flow of molten plastic material from said supply channel into two portions and to accompany said two flow portions in said injection channel
Data Source
AI summary
A component of an injection molding apparatus for conveying a flow of molten plastic material from a supply channel to an injection channel coaxially crossed by a shutter, said component comprising a body provided witha central part crossed by a through hole defining a longitudinal axis for the passage of said shutter;a first bulkhead protruding from said central part, distal from an end edge of the through hole and adapted to be arranged at one end of the supply channel for dividing the flow of molten plastic material into two portions;a second bulkhead and a third bulkhead, protruding in a diametrically opposite manner from said central part, separated from each other by the through hole and proximal to said end edge of the through hole, and adapted to be arranged at one end of the injection channel to accompany said two flow portions in said injection channel;wherein the first bulkhead is arranged on the same side as the third bulkhead with respect to said central part,and wherein a first lateral surface and a second lateral surface are arranged at a first side and a second side, opposite the first side, of said first bulkhead, respectively, to accompany said two flow portions from said first bulkhead toward the second bulkhead and the third bulkhead.