Nanocrystalline hot runner nozzle tip

Abstract

The present invention is a nozzle for an injection molding runner system where parts of the nozzle, and in particular the nozzle tip are made from a nanocrystalline material. Nanocrystalline materials used include nanocrystalline copper and nanocrystalline nickel, which have high thermal conductivity and increased material strength. A conventional form of the metal is worked till its grains are reduced in size to less than 100 nm to achieve the desired properties.

1. An injection molding nozzle for an injection molding runner system, comprising:
 a nozzle body; and 
 a nozzle tip; and 
 a melt channel extending along a longitudinal axis between the nozzle body and the nozzle tip; 
 wherein the at least one of the nozzle body and the nozzle tip is made from a nanocrystalline material. 
 
     
     
       2. The nozzle of  claim 1 , wherein the nanocrystalline material is formed from grains, and a majority of the grains are sized less than 100 nm. 
     
     
       3. The nozzle of  claim 2 , wherein at least 75% of the grains are sized less than 100 nm. 
     
     
       4. The nozzle of  claim 3 , wherein at least 75% of the grains are sized less than 50 nm. 
     
     
       5. The nozzle of  claim 4 , at least 75% of the grains are sized less than 30 nm. 
     
     
       6. The nozzle of  claim 5 , wherein a remaining percentage of the nanocrystalline material has a grain size of at least 100 nm. 
     
     
       7. The nozzle of  claim 2 , wherein the nanocrystalline material is a nanocrystalline form of a face centered cubic metal. 
     
     
       8. The nozzle of  claim 7 , wherein the nanocrystalline material is one of nanocrystalline copper, a nanocrystalline copper alloy, a nanocrystalline nickel and a nanocrystalline nickel alloy. 
     
     
       9. The nozzle of  claim 7 , wherein the nanocrystalline material is formed from a non-nanocrystalline material using one of severe plastic deformation, powder compaction or electrodeposition. 
     
     
       10. The nozzle of  claim 2 , wherein the nozzle tip is retained against the nozzle body by a tip retainer. 
     
     
       11. An injection molding nozzle tip for attachment to a nozzle for an injection molding runner system, wherein the nozzle tip is made from a nanocrystalline material. 
     
     
       12. The nozzle tip of  claim 11 , wherein the nanocrystalline material is formed from grains, and a majority of the grains are sized less than 100 nm. 
     
     
       13. The nozzle tip of  claim 12 , wherein at least 75% of the grains are sized less than 100 nm. 
     
     
       14. The nozzle tip of  claim 13 , wherein at least 75% of the grains are sized less than 50 nm. 
     
     
       15. The nozzle tip of  claim 14 , wherein at least 75% of the grains are sized less than 30 nm. 
     
     
       16. The nozzle tip of  claim 15 , wherein a remaining percentage of the nanocrystalline material has a grain size of at least 100 nm. 
     
     
       17. The nozzle of  claim 12 , wherein the nanocrystalline material is a nanocrystalline form of a face centered cubic metal. 
     
     
       18. The nozzle tip of  claim 17 , wherein the nanocrystalline material is one of nanocrystalline copper, a nanocrystalline copper alloy, nanocrystalline nickel and a nanocrystalline nickel alloy. 
     
     
       19. The nozzle tip of  claim 17 , wherein the nozzle tip is retained against a nozzle body on an by a tip retainer. 
     
     
       20. An injection molding nozzle for an injection molding runner system, comprising:
 a nozzle body; 
 a nozzle tip; and 
 a melt channel extending along a longitudinal axis between the nozzle body and the nozzle tip; 
 wherein the at least one of the nozzle body and the nozzle tip is coated with one of a nanocrystalline material and a nano-composite material. 
 
     
     
       21. The nozzle of  claim 20 , wherein the at least one of the nozzle body and the nozzle tip is coated with a nanocrystalline material using one of electrodeposition, thermal spraying, plasma spraying, pulsed laser deposition or chemical vapor deposition. 
     
     
       22. An injection molding a nozzle tip for attachment to a nozzle for an injection molding runner system, wherein the nozzle tip is coated with a one of a nanocrystalline material and a nano-composite material. 
     
     
       23. A hot runner nozzle comprising at least one component made from a nanocrystalline material. 
     
     
       24. The hot runner nozzle of claim 23, wherein the nanocrystalline material is formed from grains, and a majority of the grains are sized less than 100 nm. 
     
     
       25. The hot runner nozzle of claim 24, wherein at least 75% of the grains are sized less than 100 nm. 
     
     
       26. The hot runner nozzle of claim 25, wherein at least 75% of the grains are sized less than 50 nm. 
     
     
       27. The hot runner nozzle of claim 26, wherein at least 75% of the grains are sized less than 30 nm. 
     
     
       28. The hot runner nozzle of claim 27, wherein a remaining percentage of the nanocrystalline material has a grain size of at least 100 nm. 
     
     
       29. The hot runner nozzle of claim 24, wherein the nanocrystalline material is a nanocrystalline form of a face centered cubic material. 
     
     
       30. The hot runner nozzle of claim 29, wherein the nanocrystalline material is one of nanocrystalline copper, a nanocrystalline copper alloy, nanocrystalline nickel and a nanocrystalline nickel alloy. 
     
     
       31. The hot runner nozzle of claim 29, wherein the nanocrystalline material is formed using one of severe plastic deformation, powder compaction or electrode deposition. 
     
     
       32. The hot runner nozzle of claim 23, wherein the at least one component comprises a nozzle body. 
     
     
       33. The hot runner nozzle of claim 23, wherein the at least one component comprises a nozzle tip. 
     
     
       34. The hot runner nozzle of claim 23, wherein the at least one component comprises a tip retainer. 
     
     
       35. A hot runner nozzle wherein at least one component comprises a nanocrystalline material. 
     
     
       36. A hot runner nozzle assembly comprising at least one component that is at least partially coated with one of a nanocrystalline material and a nanocomposite material. 
     
     
       37. The hot runner nozzle assembly of claim 36, wherein the at least one component is coated with a nanocrystalline material using one of electrodeposition, thermal spraying, plasma spraying, pulsed laser deposition or chemical vapor deposition. 
     
     
       38. A hot runner nozzle comprising at least one component that is at least partially coated with one of a nanocrystalline material and a nanocomposite material. 
     
     
       39. The hot runner nozzle of claim 38, wherein the at least one component comprises at least one of a nozzle body, a nozzle tip, a tip retainer and a melt channel. 
     
     
       40. The hot runner nozzle of claim 38, wherein the at least one component is coated with a nanocrystalline material using one of electrodeposition, thermal spraying, plasma spraying, pulsed laser deposition or chemical vapor deposition.