Apparatus for runnerless injection molding thermosetting materials

Claim 2

An improved injection nozzle comprising: (a) a unitary housing member having a closed end and an open end, (b) said open end adapted to be attached to the injection barrel of an injection molding machine, (c) the interior of said closed end and the interior of said housing member forming an internal chamber, (d) said internal chamber narrowing along a portion thereof to form a constricted zone, (e) said housing member adjacent said constricted zone having operably connected means for maintaining the temperature within said constricted zone sufficiently cool to prevent any substantial curing of feed material and sufficiently warm to maintain feed material in a plasticized condition, (f) said housing member having a plurality of feed outlets positioned along the periphery thereof contiguous to said closed end, (g) said feed outlets connecting with said internal chamber; and (h) said housing having in combination, in contact with the closed end thereof, a temperature controlled plate that assists in controlling the temperature of the closed end of said nozzle.

Claim 3

An improved injection molding machine comprising: a stationary assembly comprised of: a stationary platen member, a heat plate mounted thereon, means to heat said plate, and a plurality of mold faces mounted on said heat plate; a movable assembly comprised of: a movable platen member, a heat plate mounted thereon, means for heating said plate, and a plurality of mold faces mounted on said heat plate corresponding to and adapted to be aligned with the mold faces on said stationary assembly to form a plurality of mold cavities; an injection nozzle assembly comprised of: a housing member having a closed end and an open end, said open end adapted to be attached to the injection barrel of an injection molding machine, said closed end and interior of said housing member forming an internal chamber, said internal chamber narrowing along a portion thereof to form a constricted zone, said housing member adjacent said constricted zone having operably connected means for maintaining the temperature within said constricted zone sufficiently cool to prevent any substantial curing of feed material and sufficiently warm to maintain feed material in a plasticized condition, said housing member having a plurality of feed outlets positioned along the periphery thereof contiguous to said closed end, and said feed outlets connecting with said internal chamber, means to move said movable assembly to bring said aligned mold faces into contact with corresponding mold faces in said stationary assembly to form mold cavities and runner channels adapted to feed said mold cavities, whereby said injection nozzle assembly is positioned with respect to said stationary assembly and said movable assembly such that said feed outlets are maintained in open communication with said runner channels, means for feeding a supply of plasticized thermosetting molding material into the open end of said nozzle member, through said feed outlets, then through said runner channels and into said mold cavities, and curing said thermosetting feed material enclosed within the mold cavities, and means for retracting said movable assembly to separate said mold faces and remove a molded article.

Claim 4

An improved injection molding machine comprising: a stationary assembly comprised of: a stationary platen member, a heat plate mounted thereon, means to heat said plate, and a plurality of mold faces mounted on said heat plate; a movable assembly comprised of: a movable platen member, a heat plate mounted thereon, means for heating said plate, and a plurality of mold faces mounted on said heat plate corresponding to and adapted to be aligned with the mold faces on said stationary assembly to form a plurality of mold cavities; an injection nozzle assembly comprised of: a housing member having a closed end and an open end, said open end adapted to be attached to the injection barrel of an injection molding machine, said closed end and interior of said housing member forming an internal chamber, said internal chamber narrowing along a portion thereof to form a constricted zone, said housing member adjacent said constricted zone having operably connected means for maintaining the temperature within said constricted zone sufficiently cool to prevent any substantial curing of feed material and sufficiently warm to maintain feed material in a plasticized condition, said housing member having a plurality of feed outlets positioned along the periphery thereof contiguous to said closed end, and said feed outlets connecting with said internal chamber, means to move said movable assembly to bring said aligned mold faces into contact with corresponding mold faces in said stationary assembly to form mold cavities and runner channels adapted to feed said mold cavities, whereby said injection nozzle assembly is positioned with respect to said stationary assembly and said movable assembly such that said feed outlets are maintained in open communication with said runner channels, means for feeding a supply of plasticized thermosetting molding material into the open end of said nozzle member, through said feed outlets, then through said runner channels and into said mold cavities, and curing said thermosetting feed material enclosed within the mold cavities, and means for retracting said movable assembly to separate said mold faces and remove a molded article.

Claim 5

The apparatus of claim 2 wherein the said stationary and the said movable heat plates are heated electrically.

Claim 6

The apparatus of claim 2 having operably connected means for maintaining the mold faces at a temperature between about 149° and about 204° C.

Claim 7

The apparatus of claim 2 wherein the means for cooling said nozzle assembly comprises an internal channel within said constricted zone adapted to hold a reservoir of circulating cooling liquid.

Claim 8

The apparatus of claim 5 wherein the cooling liquid is water.

Claim 9

The apparatus of claim 5 wherein the nozzle assembly has operably connected means for maintaining a temperature with the range of between about 77° and about 121° C.

Claim 10

The apparatus of claim 2 wherein the movable assembly is provided with a temperature controlled plate that is in contact with and assists in cooling the closed end of the injection nozzle assembly when the movable assembly is in contact with the stationary assembly.

Claim 11

The apparatus of claim 2 wherein said movable heat plate has a temperature-controlled area comprised of a temperature-controlled plate member aligned with the closed end of said nozzle member, said plate having operably connected means for maintaining its temperature lower than that at which any substantial curing of the thermosetting molding material will occur but sufficiently high to maintain the molding material in a plasticized condition.

Claim 12

The apparatus of claim 9 wherein said temperature-controlled plate member has operably connected means to maintain its temperature at about 77° to about 121° C.