Multi-cavity injection molding apparatus splitting melt near nozzle front

In a multi-cavity valve gated injection molding apparatus having at least one heated nozzle (12) extending forwardly into a well (14) in a cooled mold (16) with an insulative air space (60) extending between the at least one heated nozzle (12) and the surrounding cooled mold (16), the at least one heated nozzle (12) having a rear end (38), a front end (96) and a plurality of equally spaced valve pin bores (64) extending therethrough from the rear end (38) to the front end (96), a corresponding plurality of elongated valve pins (62) each received in one of the valve pin bores (64) through the at least one heated nozzle (12), and a valve pin actuating mechanism (70) connected to the valve pins (62) to simultaneously reciprocate the valve pins (62) between at least an open position and a closed position, the improvement further comprising;

• (a) the at least one heated nozzle (12) having a melt bore (50) extending therethrough from a central inlet (52) at the rear end (38),
• (b) a valve bushing (100) seated in a recessed seat (102) in the front end (96) of the at least one heated nozzle (12), the valve bushing (100) having a rear end (106), a front end (108), a plurality of equally spaced valve pin bores (104) extending therethrough from the rear end (106) to the front end (108) in alignment with the valve pin bores (64) through the at least one heated nozzle (12), and a melt bore (116) extending therethrough from the rear end (106) to the front end (108), the melt bore (116) having a plurality of front portions (118) and central rear portion (120) extending from the rear end (106) in alignment with the melt bore (50) through the at least one heated nozzle (12), each front portion (118) extending from the central rear portion (120) diagonally outwardly to each join one of the valve pin bores (104) adjacent the front end (108) of the valve bushing (100),
• (c) a retaining ring (122) seated in the recessed seat (102) in the front end (96) of the at least one heated nozzle (12) adjacent the front end (108) of the valve bushing (100), the retaining ring (122) having a rear end (126), a front end (130) and a plurality of openings (128) extending therethrough from the rear end (126) to the front end (130), each opening (128) extending in alignment with one of the valve pin bores (104) through the valve bushing (100),
• (d) a plurality of elongated hollow nozzle inserts (132), each retainably seated in one of the openings (128) through the retaining ring (122) with a front portion (140) extending forwardly from the retaining ring (122) in alignment with a gate (66) leading to a cavity (68), each nozzle insert (132) having a rear end (138), a front end (146), and a central bore (144) extending therethrough from the rear end (138) to the front end (146) to receive one of the valve pins (62) therein, with a space (147) extending around the valve pin (62) to convey melt from one of the diagonal front portions (118) of the melt bore (116) through the valve bushing (100) to the aligned gate (66), and
• (e) a nozzle seal (124) removably mounted at the front end (96) of the at least one heated nozzle (12) bridging the insulative air space (60) between the at least one heated nozzle (12) and the cooled mold (16), locating the front end (96) of the at least one nozzle (12), and retaining the valve bushing (100), the retaining ring (122), and the nozzle inserts (132) in place.