Mold Gate Insert Retainer for Injection Molding

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Solution Overview

Problem

Conventional injection molding systems face challenges in maintaining the optimal temperature of the melt stream due to heat transfer from heated nozzles to cooled mold plates, and the angular orientation of nozzle seals is difficult to reproduce during assembly and disassembly, leading to inconsistent sealing and part quality.

Innovation Solution

A hot runner system featuring a mold gate insert and retainer, where the mold gate insert is non-threadably coupled to the nozzle using a retainer with threaded surfaces, allowing for precise angular orientation and easy assembly/disassembly, while minimizing heat transfer through a cooling gate insert that contacts the mold plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the nozzle seal is threaded to the nozzle, then the seal can be securely attached, but the angular orientation of the seal cannot be repeated during removal and reinstallation

Engineering Contradiction:

Improvesealing reliabilityVSAvoidangular orientation repetition

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The seal assembly is divided into two independent components: the nozzle seal body and the retainer. The retainer is threaded to the nozzle while the seal body maintains its angular orientation through a non-threaded interface with the mold gate insert. This segmentation allows the seal to be securely attached while maintaining repeatable angular positioning during removal and reinstallation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retainer acts as an intermediary component between the nozzle and the mold gate insert. It provides the threaded connection to the nozzle while simultaneously retaining the mold gate insert at a precise angular orientation. This intermediary mechanism decouples the threading operation from the angular positioning, enabling both secure attachment and repeatable orientation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the mold gate insert is threadably secured to the nozzle, then easy assembly and disassembly is achieved, but the angular orientation cannot be maintained independently

Engineering Contradiction:

Improveassembly and disassembly easeVSAvoidangular orientation maintenance

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The connection system is segmented into the retainer (threaded to nozzle) and the mold gate insert (retained by the retainer). This allows the mold gate insert to be easily attached and detached through the retainer's threaded connection while maintaining its angular orientation through the non-threaded interface with the nozzle body.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retainer serves as an intermediary that provides the threaded connection for easy assembly while simultaneously maintaining the angular orientation of the mold gate insert. This intermediary mechanism allows independent control of the threading operation and angular positioning.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If the nozzle seal contacts the mold plate directly, then positioning stability is improved, but heat transfer from nozzle to mold plate increases

Engineering Contradiction:

Improvepositioning stabilityVSAvoidheat transfer loss

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The mold gate insert acts as an intermediary component between the nozzle and the mold plate. It provides a non-threaded interface that maintains angular orientation while reducing direct thermal contact between the heated nozzle and cooled mold plate, thereby minimizing heat transfer loss while preserving positioning stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This solution maintains the optimal melt temperature by reducing heat transfer and ensures consistent angular orientation of the mold gate insert, facilitating predictable and repeatable assembly, thereby improving the quality and consistency of molded parts.

Implementation Method 1

An outside surface of the mold gate insert retainer includes threads that mate with threads on an inside surface of the nozzle

Methodology Applied

Scientific EffectThreading: Screw

Implementation Method 2

the mold gate insert is non-threadably coupled to the nozzle body by the mold gate insert retainer. The mold gate insert contacts the mold plate adjacent the mold gate

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS7370417B2Method of installing a mold gate insert in an injection molding apparatus

Publication Date: 2008.05.13 MOLD MASTERS (2007) LIMITED

AI summary

An injection molding apparatus including an injection manifold having a manifold melt channel, a mold plate having a mold bore, and a hot runner nozzle located in the mold bore and having a nozzle melt channel. A mold insert including a melt channel includes an upper end adjacent the nozzle, a first outer surface adjacent the upper end, and a lower portion including a second outer surface, wherein the second outer surface is in sealing contact with an inner surface of the mold plate. A mold gate insert retainer includes an inner surface surrounding the first outer surface of the mold gate insert and a threaded outer surface for mating with a threaded inner surface of the nozzle. The first outer surface of the mold gate insert and the inner surface of the mold gate insert retainer are non-threaded. A lower end surface of the mold gate insert may form a wall of the mold cavity and may be angled.