Injection molding component with low profile terminal connection

1. An injection molding hot-runner component comprising:

a tubular body defining a central passage and having an outer surface;

an electrically insulated heater wire coupled to the tubular body;

an external lead electrically connected to an end of the heater wire to form a connection, the external lead for connecting to an external power supply; and

a terminal housing mounted to the outer surface of the tubular body, the connection of the external lead and the end of the heater wire being located within the terminal housing, wherein the connection extends in a plane that is generally parallel to a tangential plane to the outer surface of the tubular body at the location of the connection.

2. The injection molding hot-runner component of claim 1 , wherein the heater wire comprises a U-shaped bend, and wherein the injection molding hot-runner component further comprises another external lead that connects to another end of the heater wire to form another connection, the other connection being located within the terminal housing and extending in a plane that is generally parallel to a tangential plane to the outer surface of the tubular body at the location of the connection.

3. The injection molding hot-runner component of claim 1 , wherein the heater wire comprises a U-shaped bend, and wherein the injection molding hot-runner component further comprises another external lead that connects to another end of the heater wire to form another connection, and another terminal housing mounted to the outer surface of the tubular body, the another connection of the external lead and the another end of the heater wire being located within the another terminal housing, wherein the another connection extends in a plane that is generally parallel to a tangential plane to the outer surface of the tubular body at the location of the connection.

4. The injection molding hot-runner component of claim 1 wherein the tubular body is a cylindrical body and the outer surface is a cylindrical outer surface.

5. The injection molding hot-runner component of claim 4 , wherein the connection of the external lead and the end of the heater wire extends in a line that is parallel to a line tangential to the outer surface of the tubular body.

6. The injection molding hot-runner component of claim 4 , wherein the connection of the external lead and the end of the heater wire is generally parallel to the outer surface of the tubular body.

7. The injection molding hot-runner component of claims 1 , wherein the terminal housing comprises two pieces that are joined to form a rectangular box-like structure, with one of the pieces being located between the connection and the outer surface.

8. The injection molding hot-runner component of any claims 1 , wherein the terminal housing has a tubular shape defining an interior passage in which the connection is located.

9. The injection molding hot-runner component of claim 1 , wherein the terminal housing comprises ceramic material or polymer material.

10. The injection molding hot-runner component of claim 1 further comprising a fastener or an adhesive that fixes the terminal housing to the tubular body.

11. The injection molding hot-runner component of claim 1 , wherein the terminal housing is held adjacent to the tubular body by rigidity of at least one of the heater wire or the external lead.

12. The injection molding hot-runner component of claim 1 , wherein the outer surface of the tubular body is curved, and the terminal housing comprises an inner curved surface that mates with the curved outer surface of the tubular body.

13. The injection molding hot-runner component of claim 1 , wherein the tubular body comprises a recessed seat on the outer surface in which the terminal housing is at least partially disposed.

14. The injection molding hot-runner component of claim 1 , wherein the tubular body comprises a flat surface on the outer surface on which a flat surface of the terminal housing is positioned.

15. The injection molding hot-runner component of claim 1 further comprising a fastener that fixes the external lead and the terminal housing to the tubular body.

16. The injection molding hot-runner component of claim 1 further comprising a retaining clip that clips onto the tubular body and holds the external lead to the tubular body.

17. The injection molding hot-runner component of claim 1 further comprising a rim projecting from the tubular body and extending further from a central axis of the tubular body than the terminal housing extends from the central axis.

18. The injection molding hot-runner component of claim 1 further comprising a crimping tube that connects the heater wire to the external lead to form the connection.

19. The injection molding hot-runner component of claim 1 wherein the tubular body is part of a hot-runner nozzle segment for forming a hot-runner nozzle that is for connecting to a manifold to deliver melt to a mold cavity.

20. The injection molding hot-runner component of claim 1 , wherein the tubular body is part of a hot-runner nozzle body for connecting to a manifold to deliver melt to a mold cavity.

21. The injection molding hot-runner component of claim 1 , wherein the tubular body is part of a sleeve for disposing over a hot-runner nozzle or nozzle segment.

22. The injection molding hot-runner component of claim 21 , wherein the tubular body comprises a longitudinal slit extending between the outer surface and the central passage.

23. The injection molding hot-runner component of claim 1 , wherein the tubular body is part of a hot-runner sprue assembly.

24. The injection molding hot-runner component of claim 1 , wherein the heater wire is wrapped around the tubular body.

25. The injection molding hot-runner component of claim 1 , wherein the heater wire is at least partially embedded in the outer surface of the tubular body.

26. The injection molding hot-runner component of claim 1 , wherein the heater wire is wrapped inside the tubular body.

27. The injection molding hot-runner component of claim 26 , wherein the heater wire is at least partially embedded in an inner surface of the tubular body.

28. The injection molding hot-runner component of claim 27 , wherein the terminal housing is disposed on the outer surface of the tubular body and the tubular body comprises a hole allowing the heater wire to extend from the outer surface to the inner surface.

29. The injection molding hot-runner component of claim 1 further comprising a metal sheath that surrounds the electrically insulated heater wire.

30. The injection molding hot-runner component of claim 1 wherein the connection of the external lead and the end of the heater wire extends in a plane having an intersection angle range of between −30° to +30° with a tangential plane to the outer surface of the tubular body at the location of the connection.

31. The injection molding hot-runner component of claim 1 wherein the connection of the external lead and the end of the heater wire extends in a plane having an intersection angle range of between −10° to +10° with a tangential plane to the outer surface of the tubular body at the location of the connection.

32. An injection molding hot-runner apparatus comprising:

a manifold having a manifold melt channel therein;

a nozzle connected to the manifold, the nozzle comprising a nozzle body having an outer surface and a nozzle melt channel therethrough, the nozzle melt channel in communication with the manifold melt channel;

an electrically insulated heater wire coupled to the nozzle;

an external lead electrically connected to one end of the heater wire and another external lead electrically connected to another end of the heater wire forming connections, the external leads for connecting to an external power supply; and

an electrically insulating terminal housing connected to the outer surface of the nozzle body, at least one of the connections of the external leads and the ends of the heater wire being located within the terminal housing, wherein the at least one connection extends in a plane generally parallel to a tangential plane to the outer surface of the nozzle body at the location of the connection.

33. The injection molding hot-runner apparatus of claim 32 wherein the other of the connections of the external leads and the ends of the heater wire is also located within the terminal housing and the other connection extends in a plane that is generally parallel to a tangential plane to the outer surface of the nozzle body at the location of the connection.

34. The injection molding hot-runner apparatus of claim 32 further comprising at least a clip connected to the manifold, the clip for holding the external leads to the manifold.

35. The injection molding hot-runner apparatus of claim 32 , wherein the terminal housing is fixed to the nozzle body.

36. The injection molding hot-runner apparatus of claims 32 , wherein the heater wire is wrapped around the nozzle body and at least partially embedded in the outer surface of the nozzle body.

37. The injection molding hot-runner apparatus of claim 32 further comprising a sleeve around which the heater wire is wrapped, the sleeve disposed on the nozzle body.

38. The injection molding hot-runner apparatus of claim 32 wherein the connection of the external lead and the end of the heater wire extends in a plane having an intersection angle range of between −30° to +30° with a tangential plane to the outer surface of the nozzle body at the location of the connection.

39. The injection molding hot-runner apparatus of claim 32 wherein the connection of the external lead and the end of the heater wire extends in a plane having an intersection angle range of between −10° to +10° with a tangential plane to the outer surface of the nozzle body at the location of the connection.

40. An injection molding hot-runner nozzle component comprising:

a tubular body defining a central passage and having an outer surface;

an electrically insulated beater wire coupled to the tubular body;

an external lead for connecting to an external power supply, the external lead having a lead end connected to an end of the heater wire; and

an insulating terminal housing tangentially mounted to the outer surface of the tubular body, the connection of the lead end and the end of the heater wire being located within the terminal housing, wherein the tubular body outer surface is substantially cylindrical with a recessed seat formed therein in which the terminal housing is at least partially received.

41. The nozzle component of claim 40 wherein the nozzle component is one of a nozzle segment for use in a multi-segment nozzle, a nozzle, or a nozzle sleeve for mounting on a nozzle segment or nozzle.