Insulated modular injection nozzle system

An insulated modular injection nozzle system for use in conjunction with an injection molding machine, comprising:

• a mold gate insert having a mold gate therein;
• a nozzle assembly comprising a thermally-conductive nozzle housing and a thermally-conductive nozzle tip, said nozzle assembly defining at least one inner melt channel to receive molten resin and to direct said molten resin to said mold gate;
• at least one heater element in thermal contact with said nozzle assembly and operating to maintain said resin in a molten state through said at least one inner melt channel;
• and
• an insulating sleeve connecting said mold gate insert to said nozzle housing such that said nozzle tip is maintained adjacent said mold gate and inhibiting thermal transfer therebetween, wherein said insulating element further comprises a gap defined between said sleeve and said nozzle assembly.

Injection molding apparatus for use with a mold cavity and a mold plate, comprising:

• a nozzle assembly, coupled to the mold plate, for injecting a molten fluid into the mold cavity;
• a mold gate insert removably coupled to a thermal insulating sleeve and having an abutment portion in contact with the mold plate, said mold gate insert defining an air gap between said mold gate insert and the mold plate, said mold gate insert having an outside diameter which is smaller than an inside diameter of a throat of the mold plate so that said mold gate insert may be removed through the mold plate throat in the direction of the mold cavity;
• and
• a thermal insulating sleeve disposed between said mold gate insert and said nozzle assembly, said insulating sleeve being removably coupled to both said mold gate insert and said nozzle assembly.