Method of injection molding thermoplastic through multiple gates

In a multicavity injection molding process, a method for improving a thermoplastic's melt quality and increasing melt temperature entering a gate of each cavity of a multicavity mold and thereby improving molded part quality, wherein said improvement is achieved by the method of:

• (a) injecting a plasticated melt under pressure through a nozzle seated in a sprue bushing into a multicavity moldset melt delivery system, said delivery system including melt passageways maintained continuously in fluid communication between the sprue bushing on an upstream end and runner bushings feeding into each mold cavity on a downstream end, the melt contained in the delivery system is intermittently pressurized and depressurized with each injection cycle, and the melt always retains sufficient fluidity to flow as required when next pressurized;
• (b) displacing said melt contained in the delivery system downstream toward the mold cavities, upon each cycle's melt pressurization, the melt must pass through en route melt conditioning elements located upstream of each gate and downstream of each melt passageway, each conditioning element consisting of a male device member of generally torpedo shape housed concentrically within a generally cylindrically shaped female bushing member, a precisely dimensioned annular clearance space between the male and female members, each conditioning element defining longitudinally at least one inlet melt channel which is longitudinally substantially blocked at its downstream end and at least one outlet melt channel which is longitudinally substantially blocked at its upstream end, and said inlet and outlet melt channels are maintained in fluid communication through said precisely dimensioned clearance space defining a constrictive land interposed therebetween, such that melt transferring between said inlet and outlet melt channels must pass over said constrictive land and, furthermore, said melt transferring therebetween must undergo substantial angular change in flow direction as said inlet and outlet melt channels are not coaxially aligned, and each melt conditioning element feeding the melt directly into the gate;
• (c) shearing substantially the melt as it flows during the intermittent pressurization of each cycle, within said melt conditioning elements, thereby increasing the melt temperature and mixing the melt by angular flow direction change as the melt is transferred through said constrictive land within said melt conditioning elements;
• and
• (d) heating at least one of said male and female members of each melt conditioning element comprising heating said melt conditioning elements to a temperature greater than a temperature of the melt measured upstream of the melt conditioning elements and forcing intimate contact between the melt and said heated members at least during the intermittent pressurization, thereby increasing heat transfer between said melt and said heated members and increasing melt temperature downstream of said melt conditioning elements whereby the melt entering each mold cavity has substantially greater homogeneity, fluidity, and heat content with very minimally increased heat history;
• (e) injecting the melt into variable-volume multiple cavities positioned in the multicavity moldset, wherein each variable-volume cavity will be in a pre-enlarged state at the time when injection fill and melt pressurization first commences, so that there is minimal back pressure opposing the incoming melt caused by an aspect ratio of the final mold cavity volume as perceived by the incoming melt, since the overall cavity volume of said pre-enlarged cavity when being filled exceeds the melt's volume and is thereby not constrictive, such that a minimally oriented melt has been delivered into the pre-enlarged mold cavity and the melt is then subject to compressive redistribution and shrinkage compensation, into final part dimensions.

In a multiple gated single cavity injection molding process, a method for improving a thermoplastic's melt quality and increasing melt temperature entering a plurality of gates and thereby improving molded part quality, wherein said improvement is achieved by the method of:

• (a) injecting a plasticated melt under pressure through a nozzle seated in a sprue bushing into a multigated moldset melt delivery system, said delivery system including melt passageways maintained continuously in fluid communication between the sprue bushing on an upstream end and runner bushings feeding into each gate cavity on a downstream end, the melt contained in the delivery system is intermittently pressurized and depressurized with each injection cycle, and the melt always retains sufficient fluidity to flow as required when next pressurized;
• (b) displacing said melt contained in the delivery system downstream toward the gates feeding into the single mold cavity, upon each cycle's melt pressurization, the melt must pass through en route melt conditioning elements located upstream of each gate and downstream of each melt passageway, each conditioning element consisting of a male device member of generally torpedo shape housed concentrically within a generally cylindrically shaped female bushing member, a precisely dimensioned annular clearance space between the male and female members, each conditioning element defining longitudinally at least one inlet melt channel which is longitudinally substantially blocked at its downstream end and at least one outlet melt channel which is longitudinally substantially blocked at its upstream end, and said inlet and outlet melt channels are maintained in fluid communication through said precisely dimensioned clearance space defining a constrictive land interposed therebetween, such that melt transferring between said inlet and outlet melt channels must pass over said constrictive land and, furthermore, said melt transferring therebetween must undergo substantial angular change in flow direction as said inlet and outlet melt channels are not coaxially aligned, and each melt conditioning element feeding the melt directly into the gate;
• (c) shearing substantially the melt as it flows during the intermittent pressurization of each cycle, within said melt conditioning elements, thereby increasing the melt temperature and mixing the melt by angular flow direction change as the melt is transferred through said constrictive land within said melt conditioning elements;
• and
• (d) heating at least one of said male and female members of each melt conditioning element comprising heating said melt conditioning elements to a temperature greater than a temperature of the melt measured upstream of the melt conditioning elements and forcing intimate contact between the melt and said heated members at least during the intermittent pressurization, thereby increasing heat transfer between said melt and said heated members and increasing melt temperature downstream of said melt conditioning elements whereby the melt entering each gate of the single cavity has substantially greater homogeneity, fluidity, and heat content with very minimally increased heat history.