Cast hot runner manifold for injection molding apparatus
The present invention is an injection molding apparatus having a cast manifold. The manifold is made from a cast block and includes at least one pipe and a junction component fixed therein. The junction component has an axial bore having a first end and a second end, and at least one radial bore fluidly connected to the axial bore and having an opening to an outer surface of the junction component. A melt is introduced into the manifold and travels through the radial and axial bores of the junction component and through at least one pipe connected thereto to an injection molding nozzle for injection into a mold cavity. A manifold of the present invention may have a plurality of pipes and junction components to form a branched multi-level cast manifold.
1. An injection molding apparatus, comprising:
a manifold including,
a cast manifold block,
a junction component fixed in the manifold block and having an axial bore with a first end opening to an exterior surface of said manifold block for receiving a flow of melt material, and at least one radial bore in fluid communication with the axial bore and having at least one opening to an outer surface of said junction component, and
at least one pipe fixed in the manifold block, wherein said at least one pipe has a first end that engages said junction component at the at least one opening of said radial bore, said junction component and said at least one pipe defining a manifold channel for directing the flow of melt material;
wherein the junction component and the at least one pipe are separate pieces that the manifold block has been cast around, and
a nozzle defining a nozzle channel in fluid communication with the manifold channel for receiving the flow of melt material through said at least one pipe.
2. The apparatus of claim 1 , wherein said at least one pipe has at least one bend.
3. The apparatus of claim 1 , wherein the manifold further includes at least one nozzle pipe fixed in the manifold block and having a first end engaging a second end of said at least one pipe and located intermediate the at least one pipe and the nozzle, said nozzle pipe defining the manifold channel with the at least one pipe and the junction component.
4. The apparatus of claim 3 , wherein one of said first end of said nozzle pipe and said second end of said at least one pipe is telescopically slidable inside the other of said first end of said nozzle pipe and said second end of said at least one pipe, whereby the distance between said junction component and said nozzle is adjustable prior to casting.
5. The apparatus of claim 1 , wherein the manifold further includes:
at least one support pillar component fixed in said manifold block, said support pillar component defining an axial bore and extending a height of said manifold block; and
a valve pin extending and retracting through said manifold via said axial bore of said support pillar component and into said nozzle channel.
6. The apparatus of claim 5 , wherein said valve pin is connected to an actuation unit disposed outside of said manifold.
7. The apparatus of claim 5 , wherein said support pillar component is coupled to said at least one pipe.
8. The apparatus of claim 1 , wherein said manifold further includes a heating element fixed in said manifold block.
9. The manifold of claim 8 , wherein said heating element comprises a copper wire.
10. The apparatus of claim 8 , wherein said heating element is a coil surrounding a configuration of at least said junction component engaged with said at least one pipe.
11. The apparatus of claim 8 , wherein said heating element is a coil wrapping at least one full time around said at least one pipe.
12. The apparatus of claim 8 , wherein said manifold further includes a plurality of heating elements.
13. The apparatus of claim 1 , wherein said manifold further includes:
at least one branching junction component fixed within said manifold block and having an axial bore with a first end engaging a second end of said at least one pipe and at least one radial bore in fluid communication with said axial bore with at least one opening to an outer surface of said branching junction component, and
at least one branching pipe, wherein said at least one branching pipe has a first end that engages said at least one opening of said radial bore of the branching junction component.
14. The apparatus of claim 13 , wherein said junction component and said branching junction component support said at least one pipe and said at least one branching pipe before, during and after said manifold block is cast.
15. The apparatus of claim 1 , wherein said at least one pipe is made of stainless steel.
16. The apparatus of claim 1 , wherein said manifold block is made from a soft thermally conductive metal.
17. The apparatus of claim 16 , wherein said manifold block is made from a material selected from the group consisting of copper, copper alloys, bronze, brass, aluminum, aluminum alloys, steel, steel alloys and combinations thereof.
18. The apparatus of claim 5 , wherein said junction component and said support pillar component are made from a tool steel with a high melting point.
19. The apparatus of claim 18 , wherein at least one of said junction component and said support pillar component are made from H13 tool steel.
20. The apparatus of claim 1 , wherein said junction component includes a plurality of radial bores defining a plurality of openings to the outer surface of said junction component and wherein said manifold further includes a plurality of pipes, such that each of said plurality of pipes is fluidly connected to one of said plurality of openings.
21. The apparatus of claim 1 , wherein said first end of said axial bore of said junction component is in fluid communication with a sprue bushing.
22. The apparatus of claim 1 , wherein said junction component is a sprue bushing.
23. An injection molding apparatus, comprising:
a manifold including,
a manifold block,
a junction component fixed in the manifold block and having an axial bore with a first end opening to an exterior surface of said manifold block for receiving a flow of melt material, and a radial bore in fluid communication with the axial bore and having an opening to an outer surface of said junction component,
a radial pipe fixed in the manifold block and having a first end engaging the junction component at the opening of said radial bore, and
a nozzle pipe fixed in the manifold block and having a first end engaging a second end of said radial pipe, one of said first end of said nozzle pipe and said second end of said radial pipe being telescopically slidable inside the other,
the junction component, radial pipe and nozzle pipe defining a manifold channel for directing the flow of the melt material through said block; and
a nozzle defining a nozzle channel in fluid communication with said manifold channel for receiving the flow of melt material.
24. The apparatus of claim 23 , wherein said manifold block is a cast block.
25. The apparatus of claim 23 , wherein at least one of the pipes has at least one bend.
26. The apparatus of claim 23 , wherein said manifold further includes a heating element fixed in said manifold block.
27. The apparatus of claim 23 wherein the manifold further includes a connector disk having a central bore into which a second end of the nozzle pipe is inserted, the connector disk having a first surface that contacts the manifold block and an opposite surface that contacts an end of the nozzle.
28. An injection molding apparatus, comprising:
a manifold including,
a manifold block,
a junction component fixed in the manifold block and having an axial bore with a first end opening to an exterior surface of said manifold block for receiving a flow of melt material, and at least one radial bore in fluid communication with the axial bore and having at least one opening to an outer surface of said junction component,
at least one pipe fixed in the manifold block, wherein said at least one pipe has a first end that engages said junction component at the at least one opening of said radial bore, the junction component and at least one pipe defining a manifold channel for the flow of melt material, and
at least one support pillar component coupled to said at least one pipe and fixed in said manifold block, said support pillar component defining an axial bore and extending a height of said manifold block,
wherein the junction component, the at least one pipe, and the at least one support pillar are separate pieces that the manifold block has been cast around;
a nozzle defining a nozzle channel in fluid communication with the manifold channel for receiving the flow of melt material, and
a valve pin retractably extending through said manifold block via said axial bore of said support pillar component and into said nozzle channel.
29. The apparatus of claim 28 , wherein said manifold block is a cast block.
30. The apparatus of claim 28 , wherein said at least one pipe has at least one bend.
31. The apparatus of claim 28 , wherein said valve pin is connected to an actuation unit disposed outside of said manifold.
32. The apparatus of claim 28 , wherein said manifold further includes a heating element fixed in said block.