Injection Nozzle with Separate Channels for Multi-Material Molding
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Solution Overview
Problem
Conventional injection nozzles for moulding plastics materials cannot produce two different materials or varying shades and patterns directly, limiting the creation of decorative elements in moulded pieces.
Innovation Solution
A system with a cylindrical injection nozzle featuring separate channels for each material, a rotating mechanism, and a flow diffuser to maintain material separation until injection, allowing for simultaneous injection of two materials and rotation to create patterns and effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional injection nozzle with a single central passage is used, then the structure is simple and easy to manufacture, but it cannot produce two different materials or varying shades and patterns directly
Solution Approach 1:
The injection nozzle is divided into multiple independent channels (first injection channel and second injection channel) that remain separate throughout most of their length. Each channel can deliver different materials or colors independently, enabling the production of multi-material or multi-color molded pieces without requiring complex post-processing
Solution Approach 2:
The injection valve is positioned inside the injection nozzle, and the separate injection channels are arranged concentrically within the nozzle body. The first and second injection channels are nested within the same nozzle structure, allowing compact integration while maintaining material separation until the point of injection
2Adaptability or versatility
If materials are mixed early in the injection system, then flow distribution is simplified, but it becomes impossible to maintain material separation for decorative element formation
Solution Approach 1:
The flow diffuser is positioned to act on the materials before they enter the injection channels, pre-distributing and pre-separating the flows. This preliminary action ensures that materials remain separated as they travel through the injection system, enabling decorative element formation while simplifying the downstream channel structure
Solution Approach 2:
The flow diffuser acts as an intermediary element between the material source and the injection channels. It controls and regulates the material flows, ensuring proper separation and distribution without requiring complex valve mechanisms or flow control systems in the channels themselves
3Adaptability or versatility
If the injection nozzle is stationary, then the injection process is simple and stable, but it cannot produce spiral patterns or helical effects
Solution Approach 1:
The injection nozzle or injection valve is made rotatable, transforming from a static component to a dynamic one. This rotation capability allows the nozzle to generate spiral and helical patterns by varying the injection angle and position during the molding process, while the rotation mechanism is integrated into the existing nozzle structure to minimize added complexity
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
Enables the production of moulded pieces with varying shades, spiral, and marbled patterns by keeping materials separate until injection and rotating the channels, enhancing decorative element formation and material distribution uniformity.
Implementation Method 1
An electrical resistance is also wound spirally around the cylindrical core to heat the plastics material passing through the injection passage
Data Source
AI summary
A system for molding plastics material, includes:at least one injection nozzle (2) with a cylindrical body;at least one hot chamber (24) on which the at least one injection nozzle is mounted;at least one penetrating ram rod (15) which extends coaxially with the injection nozzle;at least two passages (4, 5) for supplying the molding material to the injection nozzle;the injection nozzle (2) including:at least one containing collar (7);at least one injection valve (11) mounted coaxially with the containing collar (7) and having a supply end (13);the injection valve (11) including:at least a first supply channel (18) for a first molding material;at least a second supply channel (19) for a second molding material;the first and second injection channels remaining separate as far as the supply end.