Laser Welded Drop Tip Nozzle for Injection Molding
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Solution Overview
Problem
In injection molding, the drop tip nozzle assembly often fails due to premature start of molten plastic flow before the manifold reaches optimal temperature, leading to increased internal pressure and rupture of the threaded connection between the drop tip and nozzle body.
Innovation Solution
A pressure-resistant drop tip nozzle assembly with a reinforcing laser weld between the drop tip body and nozzle body, combined with an internal heating insert and mechanical connection, to withstand higher pressures and maintain the molten resin at a desired temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the manifold assembly is not heated to proper operating temperature before injection molding, then the operation can start earlier improving productivity, but the internal pressure increases causing the threaded connection between drop tip and nozzle body to rupture
Solution Approach 1:
A reinforcing weld is provided between the drop tip and nozzle body in advance, creating a backup connection that prevents rupture under high pressure conditions before the manifold reaches optimal temperature. This beforehand reinforcement allows earlier operation start without compromising connection integrity.
2Reliability
If a reinforcing weld is added between drop tip and nozzle body, then the pressure resistance and reliability improve, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The mechanical threaded connection and weld reinforcement are combined into a single integrated connection system. The threads provide the primary mechanical attachment while the weld provides additional reinforcement, merging two connection methods into one unified structure that enhances reliability without proportionally increasing 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
The solution effectively prevents failure of the nozzle assembly under high pressure conditions, reducing downtime and maintaining the integrity of the drop tip and nozzle body by ensuring the molten resin remains at a suitable temperature.
Implementation Method 1
An internal heating insert is positioned within said drop tip bore
Implementation Method 2
A reinforcing weld preferably via a continuous laser weld is provided between said drop tip body and said nozzle body
Data Source
AI summary
A pressure resistant drop tip nozzle assembly for an injection molding machine having a nozzle body with a nozzle passage extending axially through said nozzle body between a nozzle inlet and a nozzle outlet. The assembly includes a drop tip which has a body connected to the nozzle outlet of said nozzle body. The drop tip has a drop tip bore extending between a drop inlet located adjacent said nozzle outlet body and a drop outlet. A tapered drop passage located at said drop outlet defines a resin flow aperture where resin leaves said drop tip. An internal heating insert is positioned within said drop tip bore. The drop tip body is connected to the nozzle body via a mechanical connection such as screw threads. A reinforcing weld preferably via a continuous laser weld is provided between said drop tip body and said nozzle body.