Ultrasonic flow meter including reflectors positioned by injection molding tool

A flow insert forming mold for an ultrasonic flow meter, comprising

• a mold body configured to be used to form a plurality of flow inserts in an injection molding process, the mold body including
• a flow insert body formed by injection molding within the mold body and configured to define an ultrasonic signal path through a flow channel formed in each flow insert that will reflect an ultrasonic signal back and forth across the flow channel based on machined surfaces of the mold;
• and
• one or more reflectors positioned in the mold body prior to injection molding and integrated within the flow insert body during the injection molding and providing ultrasonic signal reflection along the ultrasonic signal path.

A computer-implement method for using a mold in forming a flow insert for an ultrasonic flow meter, comprising

• positioning one or more reflectors in a flow insert cavity of a mold body configured to be used to form a plurality of flow inserts in an injection molding process that are wherein the cavity receives plastic by injection molding and defines an ultrasonic signal path through a flow channel formed in each flow insert that will reflect an ultrasonic signal back and forth across the flow channel based on machined surfaces of a mold;
• fixing the one or more reflectors in position along the ultrasonic signal path extending into the flow insert cavity that will reflect the ultrasonic signal along the ultrasonic signal path across the flow channel formed in the flow insert;
• and
• forming a flow insert body by injection molding to form each flow insert that includes one or more reflectors integrated within the flow insert body during the injection molding and providing ultrasonic signal reflection along the ultrasonic signal path.