Note: Descriptions are shown in the official language in which they were submitted.
CA 02412802 2002-12-16
WO 01/96090 PCT/CA01/00910
-1-
Title: THERMALLY BALANCED HOT RUNNER NOZZLE
FIELD OF THE INVENTION
This invention relates to molding machines and in particular to
nozzles for molding machines.
BACKGROUND OF THE INVENTION
Molding machines include hot runner nozzles that define a
melt channel for passing molten material to a desired location such as a
mold cavity. It is important that the molten material be kept at a desired
temperature to ensure that it flows and cures properly. Typically, hot runner
nozzles are heated with a resistance heater that is wound about the outer
surface of the nozzle body. A thermocouple is disposed within the nozzle
body to sense the body temperature and the resistance heater is operated
by a control system to maintain the body at a desired temperature.
A problem with such conventional nozzles is that the
temperature within the nozzle varies over the length of the nozzle body.
Usually, the ends of the nozzle tend to be much cooler than the middle
portion of the nozzle due to heat loses occurring at the ends. As a result, it
is difficult to maintain the melt within the melt channel at a constant
desired
temperature. This is problematic in particular for molten materials that are
sensitive to minor changes in temperature. If the temperature is increased
too much then the melt will burn in the middle portion of the nozzle, and if
the
temperature is decreased to avoid burning then the melt might have flow
problems or other problems that will effect its ability to cure properly
within
the mold cavities.
There is a need for an apparatus to heat the melt channel
within a nozzle body to a desired temperature that remains relatively
constant over the length of the nozzle.
CA 02412802 2002-12-16
WO 01/96090 PCT/CA01/00910
SUMMARY OF THE INVENTION
In one aspect the invention provides a nozzle for a molding
machine comprising:
a nozzle body defining a melt channel;
a heater connected to said nozzle body along at least a portion
of the length of said nozzle body; and
at least one heat distributor connected to said nozzle body,
said heat distributor being formed of a conductive material for distributing
heat from said heater along said nozzle body.
BRIEF DESCRIPTION OF THE DRAWINGS
For a befiter understanding of the present invention, and to
show more clearly how it may be carried into effect, reference will now be
made by way of example to the accompanying drawings. The drawings
show preferred embodiments of the present invention, in which:
Fig. 1 is a graph of nozzle temperature over the length of a
nozzle;
Fig. 2 is a sectional view of a nozzle in accordance with the
present invention;
Fig. 3 is a transverse sectional view of the nozzle of Fig. 2 taken
along lines 3-3;
Fig. 4 is a sectional view of a second embodiment of nozzle in
accordance with the present invention;
Fig. 5 is a transverse sectional view of the nozzle of Fig. 4 taken
along lines 5-5;
Fig. 6 is a sectional view of a third embodiment of nozzle in
accordance with the present invention;
Fig. 7 is a transverse sectional view of the nozzle of Fig. 6 taken
along lines 7-7;
Fig. 8 is a transverse sectional view of the nozzle of Fig. 6 taken
along lines 8-8;
CA 02412802 2002-12-16
WO 01/96090 PCT/CA01/00910
-3-
Fig. 9 is a transverse sectional view of the nozzle of Fig. 6 taken
along lines 9-9.
Fig. 10 is a sectional view of a fourth embodiment of nozzle in
accordance with the present invention;
Fig. 11 is a transverse sectional view of the nozzle of Fig. 10
taken along lines 11-11;
Fig. 12 is a sectional view of a fifth embodiment of nozzle in
accordance with the present invention;
Fig. 13 is a transverse sectional view of the nozzle of Fig. 12
taken along lines 13-13;
Fig. 14 is a transverse sectional view of a sixth embodiment of
nozzle in accordance with the present invention; and
Fig. 15 is a schematic view of an injection molding machine
with nozzles in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to Fig. 1, a temperature profile over the length of a
conventional hot runner nozzle is shown at 10. The profile 10 shows lower
temperatures 12 at the ends of the nozzle and higher temperatures 14 at the
middle of the nozzle. A desired temperature profile for a nozzle in
accordance with the present invention is shown at 16. The desired
temperature is relatively constant over the length of the nozzle.
Referring to Figs. 2 and 3, a nozzle in accordance with a first
embodiment of the present invention is shown generally at 20. The nozzle
20 includes a body 22 that defines a melt channel 24. Nozzle body is
typically formed of steel or other suitable materials known to persons skilled
in the art. The nozzle has an inlet 26 defined at a first end 28 and an outlet
defined at a second end 32. Second end 32 typically is defined as a
frustoconical tip. A collar 34 is defined at the first end for mounting the
nozzle 20 to a manifold 36.
30 Nozzle 20 includes a continuous channel 40 defined in its
outer surface for receiving a resistance heater, such as for example a coil
CA 02412802 2002-12-16
WO 01/96090 PCT/CA01/00910
-4-
heater 42. Examples of suitable resistance heaters are disclosed in US
Patents 4557685, 5266023 and 5704113 which are all hereby incorporated
by reference. Resistance coil heater 42 is wound over the length of the
nozzle and is preferably disposed fully within channel 40 such that the outer
surface of the heater 42 lies generally flush with the outer surface of the
nozzle body 22. Heater 42 may be secured to channel 40 with a press
friction fit or through metalurgical bonding such as brazing or other securing
means known to persons skilled in the art. A thermocouple 44 is disposed
in nozzle body 22 for sensing the temperature of the nozzle body 22 adjacent
to melt channel 24. Heater 42 is coupled to a power supply 46 for powering
the heater 42. The thermocouple 44 and heater 42 are connected to a
control system (not shown) that monitors the temperature of nozzle body 22
and operates heater 42 as required to maintain desired temperature profile
16. A manifold heater 48 is disposed in manifold 36 to similarly heat molten
material passing through a manifold melt channel 52.
A heat distributor 60 is disposed on nozzle body 22 over a
desired portion of its length. Heat distributor 60 is formed of a conductive
material such as copper or a copper alloy that will conduct heat produced by
heater 42 along the length of heat distributor 60. Heat distributor 60 may be
preformed as a hollow sleeve that is closely fitted to nozzle body by means
of a friction fit or by means of braising, welding, or other attachment
methods known to those skilled in the art. Alternatively, heat distributor 60
may be applied to the outer surface of nozzle body 22 by spraying or dipping
the conductive material directly onto nozzle body 22. Preferably, heat
distributor 60 is in direct physical contact with heater 42 and with nozzle
body 22 in order that an optimum heat transfer and distribution can be
achieved. As a result, heat distributor 60 acts to distribute heat
sufficiently
over its length to produce a relatively constant temperature profile 16 over
the corresponding length of nozzle 20.
Referring to Figs. 4 and 5, a second embodiment of nozzle 20
in accordance with the present invention is shown. For convenience,
CA 02412802 2002-12-16
WO 01/96090 PCT/CA01/00910
-5-
corresponding elements as described above are assigned corresponding
reference numbers.
In the second embodiment of nozzle 20, nozzle body 22 has
heat distributor 60 disposed upon its outer surFace. A hollow heater sleeve
70 is then disposed on the outer surface of heat distributor 60. Heater
sleeve 70 defines continuous channel 40 for receiving heater 42. Heater 42
is connected to power supply 46 for powering the heater 42. A second heat
distributor 60' is disposed externally of heater sleeve 70 to further aid in
distributing heat along the desired length of nozzle body 22. A thermal
insulator 72 such as a ceramic or other suitable insulation material known
to those skilled in the art may in some instances be disposed externally to
heat distributor 60'.
Referring to Figs. 6 - 9, a third embodiment of nozzle in
accordance with the present invention is shown. Again, for convenience,
corresponding elements to the embodiments described above are given
corresponding reference numbers.
The third embodiment of nozzle 20 includes nozzle body 22
which defines in its outer surface continuous channel 40 for receiving heater
42. Nozzle body 22 is configured to include a reduced diameter portion 80
at an intermediate region between the first and second ends 26, 32 of
nozzle 20. Reduced diameter portion 80 provides a region of heat loss to
reduce the likelihood of high temperature 14 in the intermediate region of
nozzle 20. Reduced diameter portion 80 provides a smaller mass to transfer
less heat from the heater 42 to the molten material flowing through the melt
channel.
Heater 42 is also disposed at second end .32 of nozzle body 22
for maintaining temperature of the melt within nozzle body 22 prior to exiting
from outlet 30.
Heat distributor 60 is disposed on nozzle body 22 for
distributing heat along the length of nozzle body 22 to achieve relatively
constant temperature profile 16. Heat distributor 60 includes apertures 82
overlying reduced diameter portions 80 of nozzle body 22 to allow heat loss
CA 02412802 2002-12-16
WO 01/96090 PCT/CA01/00910
-6-
over the intermediate region of nozzle body 22. Heat distributor 60 also is
disposed at second end 32 of nozzle body 22 to distribute heat over the
length of second end 32. The location of heat distributor 60 on second end
32 is of particular utility when second end 32 is formed as by frustoconical
tip where it is difficult to dispose heater 42 adjacent to outlet 30.
Referring to Figs. 10 - 11, a fourth embodiment of nozzle in
accordance with the present invention is shown. Again, for convenience,
corresponding elements to the embodiments described above are given
corresponding reference numbers.
The fourth embodiment of nozzle 20 includes nozzle body 22
with melt channel 24. Heater 42 is a film heater such as is disclosed in the
following patents which are hereby incorporated by reference: EP963829,
EP312029, W00023245, and W00117317. Surrounding film heater 42 is
an electrical insulator 90 that protects the film heater 42. Heat distributor
60
is then disposed over electrical insulator 90.
Referring to Figs. 12 - 13, a fifth embodiment of nozzle in
accordance with the present invention is shown. For convenience,
corresponding elements to the embodiments described above are given
corresponding references numbers.
The fifth embodiment of nozzle 20 includes nozzle body 22 that
defines melt channel 24. Nozzle heater 42 is in the form of a resistance
wire that is disposed in a dielectric material disposed around nozzle body
22. Nozzle heater 42 includes a first dielectric layer 92 that is disposed
over
nozzle body 22. A resistive wire 94 is then wrapped around nozzle body 22
over first dielectric layer 92. A second dielectric layer 96 is then disposed
over resistive wire 94 and first dielectric layer 92. This type of heater 42
is
described in more detail in PCT application PCT/CA01/00274 which is
hereby incorporated by reference. Heat distributor 60 is disposed over
second dielectric layer 96 in order to distribute heat from resistance wire
heater 42 over the length of heat distributor 60.
Referring to Fig. 14, a sixth embodiment of nozzle 20 in
accordance with the present invention is shown. Again, for convenience,
CA 02412802 2002-12-16
WO 01/96090 PCT/CA01/00910
_7_
corresponding elements to the embodiments described above are given
corresponding reference numbers.
The sixth embodiment of nozzle 20 is similar to the first
embodiment described above. Nozzle 20 includes nozzle body 22 which
defines in its outer surface continuous channel 40 for receiving heater 42.
Heat distributor 60 is disposed on nozzle body 22 over a desired portion of
its length. Heat distributor 60 includes a longitudinal slit 98 to
accommodate thermocouple 44 so that the thermocouple 44 may be
disposed against nozzle body 22.
Referring to Fig. 15, a schematic view of an injection molding
machine 100 is shown with nozzles 20 in accordance with the present
invention. For convenience, corresponding elements to the embodiments
described above are given corresponding reference numbers.
The injection molding machine 100 includes an inlet nozzle
102 that is connected to manifold 36. Manifold 36 includes melt channel
104 for distributing melt from inlet nozzle 102 to injection nozzles 20.
Injection nozzles 20 include collar 34 for mounting injection nozzles 20 to
manifold 36. Injection nozzles 20 are connected to mold cavity 106 in known
manner for introducing the molten material into mold cavity 106. Injection
nozzle 20 include nozzle body 22 that is heated with heater 42. Heat
distributor 60 is disposed over nozzle body 22 for distributing heat from
heater 42 over the length of heat distributor 60. Heat distributor 60 thus
acts
to distribute heat sufficiently over its length to produce a relatively
constant
temperature profile 16 over the corresponding length of nozzle 20.
It is to be understood that what has been described is a
preferred embodiment to the invention. If the invention nonetheless is
susceptible to certain changes and alternative embodiments fully
comprehended by the spirit of the invention as described above, and the
scope of the claims set out below.
