Molded article with selectively varied core layer geometry and hot runner nozzles for producing same

A hot runner nozzle for conveying melt to a mold cavity, the hot runner nozzle comprising:

• an inner nozzle insert defining an inner flow channel, the inner flow channel including
• an inner outlet;
• an intermediate nozzle insert disposed around the inner nozzle insert,
• the intermediate nozzle insert and the inner nozzle insert defining an intermediate flow channel, the intermediate flow channel including an intermediate outlet;
• and
• an outer nozzle insert disposed around the intermediate nozzle insert,
• the outer nozzle insert and the intermediate nozzle insert defining an outer flow channel, the outer flow channel including an outer outlet,
• the inner nozzle insert being formed such that the intermediate outlet has a non-uniform cross-section.

A hot runner nozzle for conveying melt to a mold cavity, the hot runner nozzle comprising:

• an inner nozzle insert defining an inner flow channel;
• an intermediate nozzle insert disposed around the inner nozzle insert,
• the intermediate nozzle insert and the inner nozzle insert defining an intermediate flow channel;
• and
• an outer nozzle insert disposed around the intermediate nozzle insert,
• the outer nozzle insert and the intermediate nozzle insert defining an outer flow channel,
• flow of material through the intermediate flow channel, when the hot runner nozzle is in use, being non-uniformly distributed about a longitudinal axis of the hot runner nozzle, the non-uniformity of the flow being attributable to surfaces of the intermediate nozzle insert and the inner nozzle which define the intermediate flow channel,
• the mold cavity being for defining, in use, a molded article having a core layer and a skin layer surrounding the core layer, the core layer formed from material flowing through the intermediate flow channel, the core layer having a non-uniform radial thickness about a longitudinal axis of the molded article.