Melt redistribution element for an injection molding apparatus
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-045/00
B29C-045/20
출원번호
UP-0242038
(2005-10-04)
등록번호
US-7614872
(2009-11-23)
발명자
/ 주소
Olaru, Gheorghe
Goslinski, Rhonda
출원인 / 주소
Mold Masters (2007) Limited
대리인 / 주소
Medler Ferro PLLC
인용정보
피인용 횟수 :
3인용 특허 :
35
초록▼
An injection molding apparatus having a manifold and several manifold melt channels communicating with several hot runner nozzles includes a melt redistribution element. The melt redistribution element is placed at specific locations along the melt channels to balance the uneven shear stress profile
An injection molding apparatus having a manifold and several manifold melt channels communicating with several hot runner nozzles includes a melt redistribution element. The melt redistribution element is placed at specific locations along the melt channels to balance the uneven shear stress profile accumulated during the flow of a melt along the manifold channels. The melt redistribution element has an unobstructed central melt bore having at its inlet a narrowing tapered channel portion. The melt redistribution element also includes a helical melt pathway portion that surrounds the central melt bore. The incoming melt is first subjected to a pressure increase by the tapered portion that causes the melt to flow at a higher velocity through the central melt bore. The outer portion of the melt is forced to flow along the helical path and thus it changes direction multiple times and partially mixes with the melt flowing through the central melt bore. Accordingly, at the outlet of the melt redistribution element the shear stress profile is more evenly distributed than at the inlet of the redistribution element.
대표청구항▼
What is claimed is: 1. An injection molding apparatus comprising: an injection manifold having a manifold inlet for receiving a melt stream of moldable material under pressure, a plurality of manifold melt channels and a plurality of melt channel outlets; and a melt redistribution element in fluid
What is claimed is: 1. An injection molding apparatus comprising: an injection manifold having a manifold inlet for receiving a melt stream of moldable material under pressure, a plurality of manifold melt channels and a plurality of melt channel outlets; and a melt redistribution element in fluid communication with one of said plurality of manifold channels, said melt redistribution element including an inlet and an outlet, wherein said melt redistribution element includes a melt bore pathway from said inlet to said outlet, the melt bore pathway being unobstructed from said inlet to said outlet, and a helical melt pathway formed around at least a portion of said melt bore pathway. 2. The injection molding apparatus of claim 1, wherein said redistribution element includes an inlet tapered section positioned between said inlet and said helical melt pathway, wherein said inlet tapered section has a gradually decreasing diameter. 3. The injection molding apparatus of claim 1, wherein a central portion of the melt stream flows through the melt bore and an outer portion of the melt stream flows through the helical melt pathway. 4. The injection molding apparatus of claim 1, wherein said melt stream exiting said melt redistribution element has a more uniform cross-sectional profile of at least one parameter selected from the group consisting of temperature, viscosity, shear-stress, velocity and pressure than said melt stream entering said melt redistribution element. 5. The injection molding apparatus of claim 1, wherein said melt redistribution element includes an outlet tapered section positioned between said helical melt pathway and said outlet of said melt redistribution element, wherein said outlet tapered section has a gradually increasing diameter. 6. The injection molding apparatus of claim 1, wherein said melt bore further comprises a first bore section having a first bore diameter about equal to a channel diameter of said manifold channel and a second bore section with a second bore diameter that is less than said first bore diameter. 7. The injection molding apparatus of claim 1, wherein a depth of said helical melt pathway measured from a surface of said melt bore is constant along said melt bore. 8. The injection molding apparatus of claim 1, wherein a depth of said helical melt pathway measured from a surface of said melt bore gradually decreases towards said outlet. 9. The injection molding apparatus of claim 1, wherein a depth of said helical melt pathway measured from said melt bore gradually decreases towards outlet. 10. The injection molding apparatus of claim 1, wherein said manifold includes a first manifold plate and a second manifold plate and wherein said melt redistribution element is positioned between said first and second manifold plates. 11. The injection molding apparatus of claim 10, wherein said melt redistribution element is positioned within a recess formed in each of said first and second manifold plates. 12. The injection molding apparatus of claim 1, wherein said manifold includes a plug having a bore for receiving said melt redistribution element. 13. The injection molding apparatus of claim 1, wherein said manifold channel has a first turn and said melt redistribution element is placed upstream from said first turn. 14. The injection molding apparatus of claim 1, wherein said manifold channel has a first turn and said melt redistribution element is placed downstream from said first turn. 15. The injection molding apparatus of claim 1, wherein said manifold channel has a first turn and a second turn and said melt redistribution element is placed downstream of said first turn and upstream of said second turn. 16. The injection molding apparatus of claim 1, wherein said manifold channel has a first turn and a second turn and said melt redistribution element is placed downstream of said second turn. 17. The injection molding apparatus of claim 1, wherein said manifold channel includes a split into two branches and said melt redistribution element is placed downstream of said split. 18. The injection molding apparatus of claim 1, wherein said melt redistribution element communicates with said manifold channel just upstream of said manifold outlet. 19. The injection molding apparatus of claim 1, wherein said manifold channel includes more than one melt redistribution element. 20. The injection molding apparatus of claim 1, wherein said melt redistribution element is maintained in position within said manifold channel via a fastener. 21. A method for redistributing a melt stream within a manifold of an injection molding apparatus, comprising: allowing a central portion of the melt stream to flow unobstructed along an axis of a manifold channel; and allowing an outer portion of the melt stream to flow along a helical path around said central portion, wherein said axis is parallel to the melt upstream of said helical path. 22. The method of claim 21, wherein the axis is coaxial with the melt stream upstream of the helical path. 23. The method of claim 21, farther comprising the step of providing a melt redistribution element having an inlet, an outlet, and a longitudinal axis, wherein the longitudinal axis of the melt redistribution element is parallel to the axis of the central portion and wherein the flow along the helical path is within the melt redistribution element. 24. The method of claim 23, wherein the central portion of the melt stream flows along the axis from the inlet to the outlet of the melt redistribution element. 25. A method for redistributing a melt stream within a manifold of an injection molding apparatus, comprising: providing a melt redistribution element in the manifold, the melt redistribution element having an inlet and an outlet; and passing the melt stream through said melt redistribution element such that a central portion of the melt stream passes unobstructed from said inlet to said outlet and an outer portion of the melt stream flows helically around at least a portion of said central portion such that the melt stream has a more uniform profile at said outlet of said melt redistribution element than at said inlet of said melt redistribution element. 26. The method of claim 25, wherein the central portion of said melt stream from said inlet to said outlet has a longitudinal axis that is parallel to a longitudinal axis of the melt redistribution element. 27. The method of claim 26, wherein the longitudinal axis of the central portion from said inlet to said outlet and the longitudinal axis of the melt redistribution element are coaxial. 28. The method of claim 25, wherein the melt redistribution element is provided after a bend or split in a melt channel of the manifold. 29. The method of claim 25, wherein the step of passing the melt stream through said melt redistribution element further comprises increasing the pressure of the melt stream between the inlet of the melt redistribution element and the helically flowing melt stream. 30. An injection molding apparatus comprising: an injection manifold having a manifold inlet for receiving a melt stream of moldable material under pressure, and a manifold melt channel; and a melt redistribution element in fluid communication with said manifold channel, said melt redistribution element including an inlet and an outlet, wherein said melt redistribution element includes a melt bore pathway having a longitudinal axis from said inlet to said outlet that is parallel to a longitudinal axis of the melt redistribution element, and a helical melt pathway formed around at least a portion of said melt bore pathway. 31. The injection molding apparatus of claim 30, wherein the longitudinal axis of the melt bore pathway from said inlet to said outlet is coaxial with the longitudinal axis of the melt redistribution element. 32. The injection molding apparatus of claim 30, further comprising an injection molding nozzle coupled to the manifold, the injection molding nozzle including a nozzle melt channel for receiving the melt stream from the manifold and delivering the melt stream to a mold cavity. 33. The injection molding apparatus of claim 30, wherein said manifold includes a plurality of manifold channels having outlets, and wherein a plurality of injection molding nozzles including nozzle melt channels are coupled to said manifold for receiving said melt stream from said outlets and delivering the melt stream to at least one mold cavity. 34. The injection molding apparatus of claim 33, further comprising a heater coupled to said manifold and heaters coupled to said nozzles. 35. The injection molding apparatus of claim 1, farther comprising a plurality of injection molding nozzles including nozzle melt channels coupled to said manifold for receiving said melt stream from said outlets. 36. The injection molding apparatus of claim 35, further comprising a heater coupled to said manifold and heaters coupled to said nozzles. 37. The injection molding apparatus of claim 35, wherein said melt redistribution element communicates with said manifold channel just upstream of one of said nozzles.
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