Injection Nozzle Component Geometry for Uniform Melt Flow
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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 parts such as non-constant wall thickness in preforms and variations in thickness or perpendicularity in test tubes, due to different flow speeds and stagnation zones.
Innovation Solution
A component with a specific geometry that divides the molten plastic material flow into two portions before entering the injection channel, using bulkheads and lateral surfaces to ensure similar speed profiles and uniform flow distribution.
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 the injection nozzle and the 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, leading to stagnation zones and defects in molded parts
Solution Approach 1:
The invention divides the single injection channel into two separate channels by introducing a partition wall. This segmentation allows the material flow to be split into two portions that can be controlled independently, eliminating the non-uniform flow zones created by the shutter while maintaining the ability to control material flow to the molding cavity.
Solution Approach 2:
The invention extracts and removes the shutter component from the system by replacing it with a partition wall structure. This eliminates the source of the flow uniformity problem while still achieving the desired control over material flow distribution to the molding cavity through the divided channels.
2Reliability
If the outlet channel has an annular section due to the shutter geometry, then the shutter can be held in position with a guide body, but two zones with different flow speeds are created causing stagnation zones and material defects
Solution Approach 1:
The invention segments the single outlet channel into two separate channels using a partition wall. This division eliminates the annular section geometry that causes different flow speeds, allowing material to flow uniformly through both channels without creating stagnation zones or harmful flow patterns.
Solution Approach 2:
Instead of using a shutter that creates an annular section and positioning it with a guide body, the invention inverts the approach by using a partition wall to create two separate circular sections. This inversion eliminates the harmful annular geometry while maintaining reliable control over material flow.
3Device complexity
If material flows through a single injection channel with a shutter, then the structure is simple, but defects such as non-constant wall thickness in preforms and variations in thickness or perpendicularity in test tubes occur
Solution Approach 1:
The invention divides the single injection channel into two separate channels with a partition wall, creating a more complex internal structure that eliminates flow uniformity problems. This segmentation ensures consistent material flow distribution, preventing defects like non-constant wall thickness in preforms and dimensional variations in test tubes.
Solution Approach 2:
The invention applies different flow path configurations to different portions of the material flow by creating two separate channels. Each channel provides optimized local flow conditions, ensuring uniform material distribution and consistent product quality throughout the molded part, rather than having a single uniform channel structure.
Data Source
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AI summary
A component (1) of an injection molding apparatus to divert a flow of molten plastic material from a supply channel (21) to an injection channel (22) coaxially crossed by a shutter (23), said component comprising a body (2) provided with - a central part (10) crossed by a through hole (3), defining a longitudinal axis (X), for the passage of said shutter; - a first bulkhead (4); - a second bulkhead (5) and a third bulkhead (6), protruding in a diametrically opposite manner from said central part (10), separated from each other by the through hole (3); wherein the first bulkhead (4) has a first end edge (41) which is distal from the central part (10), and wherein the thickness of the first bulkhead (4) gradually increases from the first end edge (41) towards said central part (10).