Injection Molding Nozzle Heating Element with Nested Insulating Body
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Solution Overview
Problem
Existing heating elements for flow channels and mold cavities in injection molding technology face challenges with high overall height, mechanical stress, and unreliable electrical connections due to exposure to high temperatures, vibrations, and limited space, which can lead to connection failure.
Innovation Solution
A compact heating element with a carrier element and connecting device featuring crimped connecting pins and a receiving sleeve, where the insulating body is fixed within the sleeve, reducing overall height and enhancing stability against mechanical loads, and incorporating a grounding conductor for strain relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heating element with connecting pins and insulating body is used in injection molding, then heating function is provided, but the overall height becomes too large requiring additional space
Solution Approach 1:
The insulating body is arranged at least partially inside the receiving sleeve, creating a nested structure where one component is housed within another. This reduces the overall height of the connection device while maintaining all necessary functional elements (heating conductor, insulating body, electrical connection)
Solution Approach 2:
The connection device transitions from a protruding structure to a compact integrated structure by arranging components in a nested configuration along the longitudinal axis, reducing the height dimension while preserving electrical connection functionality
2Temperature
If heating elements are mounted externally on material tube, then heating function is achieved, but connections are exposed to high temperatures and mechanical stress
Solution Approach 1:
The receiving sleeve integrates multiple functions: it provides mechanical support for the insulating body, protects electrical connections from environmental stress, and anchors the heating element assembly to the material tube. This merging of functions into a single integrated component enhances connection reliability
Solution Approach 2:
The receiving sleeve acts as a protective structure that anticipates and shields the electrical connections from high temperatures, vibrations, and mechanical stress before these environmental factors can cause damage. The sleeve creates a protected zone for vulnerable components
3Volume of moving object
If limited space is available for heating element connections, then compact design is needed, but reliable electrical connection becomes difficult to achieve
Solution Approach 1:
By nesting the insulating body within the receiving sleeve, the design achieves compact dimensions suitable for limited spaces while maintaining all necessary electrical connection elements. The nested arrangement eliminates wasted space while preserving connection integrity
Solution Approach 2:
The receiving sleeve provides a curved, encompassing structure that efficiently contains the insulating body and connecting pins in a compact volume. This geometric approach maximizes space utilization while maintaining structural integrity and electrical connection reliability
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 compact electrical connection that withstands mechanical stresses and vibrations, ensuring consistent heating performance while minimizing space requirements.
Implementation Method 1
an electrical conductor which generates heat when an electrical voltage is applied or an electric current flows through it
Implementation Method 2
a first crimp sleeve (64) is fixed on the first terminal pin (21) and a second crimp sleeve (65) is fixed on the second terminal pin (22), each by plastic deformation
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a heating element (1) for heating a flow channel or a mold cavity, comprising a support element (10) which carries a heating conductor (20) with a first connecting pin (21) and a second connecting pin (22), and comprising a connection device (30) with an electrical connecting cable (40) having a first and second conductor (41, 42), wherein the first and second connecting pins (21, 22) terminate in an insulating body (50) of the connection device (30), wherein the insulating body (50) is arranged at least partially in a receiving sleeve (60) of the connection device (30), and wherein the receiving sleeve (60) has a first end (61) pointing towards the support element (10), is fixed to the support element (10) with its first end (61), and secures the insulating body (50) relative to the support element (10).and wherein a first crimp sleeve (44) is fixed on the first connecting pin (21) and a second crimp sleeve (45) is fixed on the second connecting pin (22), each by plastic deformation, and the first crimp sleeve (44) is fixed on the first conductor (41) and the second crimp sleeve (45) is fixed on the second conductor (42), each by plastic deformation. The invention also relates to an injection molding nozzle (100) whose material tube (102) is thermally coupled to such a heating element (1).