Abstract:
An injection molding apparatus comprising: a manifold, a nozzle, A distal tip of the nozzle being comprised of a highly heat conductive insert and an insulation cap that is substantially less heat conductive than the insert, the downstream end portion of the insulation cap being disposed between the gate and the downstream end portion of the highly heat conductive insert forming a fluid seal around the gate, a valve pin, wherein when the valve pin is in a gate closed position, an axially interior surface of a fluid exit aperture of the insulation cap surrounds a gap enabling circumferential surface of the valve pin forming a spatial gap immediately upstream of the gate between the interior surface of the fluid exit aperture of the insulation cap and the gap enabling circumferential surface of the valve pin.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation of and claims the benefit of priority to PCT/US2015/010270 filed Jan. 8, 2015 which in turn claims the benefit of priority to U.S. provisional application Ser. No. 61/924,998 filed Jan. 8, 2014. 
         [0002]    The disclosures of all of the following are incorporated by reference in their entirety as if fully set forth herein: International Application Publication No. WO2012/074879, U.S. Patent Application Publication No. 2012/0248644, International Application Publication No. 2012/087491, U.S. Patent Application Publication No. 2012/0248652, U.S. Pat. No. 5,894,025, U.S. Pat. No. 6,062,840, U.S. Pat. No. 6,294,122, U.S. Pat. No. 6,309,208, U.S. Pat. No. 6,287,107, U.S. Pat. No. 6,343,921, U.S. Pat. No. 6,343,922, U.S. Pat. No. 6,254,377, U.S. Pat. No. 6,261,075, U.S. Pat. No. 6,361,300 (7006), U.S. Pat. No. 6,419,870, U.S. Pat. No. 6,464,909 (7031), U.S. Pat. No. 6,599,116, U.S. Pat. No. 7,234,929 (7075US1), U.S. Pat. No. 7,419,625 (7075US2), U.S. Pat. No. 7,569,169 (7075US3), U.S. patent application Ser. No. 10/214,118, filed Aug. 8, 2002 (7006), U.S. Pat. No. 7,029,268 (7077US1), U.S. Pat. No. 7,270,537 (7077US2), U.S. Pat. No. 7,597,828 (7077US3), U.S. patent application Ser. No. 09/699,856 filed Oct. 30, 2000 (7056), U.S. patent application Ser. No. 10/269,927 filed Oct. 11, 2002 (7031), U.S. application Ser. No. 09/503,832 filed Feb. 15, 2000 (7053), U.S. application Ser. No. 09/656,846 filed Sep. 7, 2000 (7060), U.S. application Ser. No. 10/006,504 filed Dec. 3, 2001, (7068) and U.S. application Ser. No. 10/101,278 filed Mar. 19, 2002 (7070), U.S. application Ser. No. 13/484,366 filed May 31, 2012 (7100US1) and U.S. application Ser. No. 13/484,408 filed May 31, 2012 (7100US3). 
     
    
     BACKGROUND OF THE INVENTION 
       [0003]    Injection molding systems using valve pins having cylindrical or conical geometries have been used in injection molding systems where withdrawal and closure of the pins have been controlled in an attempt to reduce vestiges on parts produced. 
       SUMMARY OF THE INVENTION 
       [0004]    In accordance with the invention and with reference to  FIGS. 2-5 , there is provided an injection molding apparatus  10  comprising: 
         [0005]    a manifold  30  having a manifold channel  35  that receives an injection fluid  32 , 
         [0006]    a nozzle  50  having a nozzle channel  54  having an axis A receiving the injection fluid from the manifold channel  35 , the nozzle having a distal tip in fluid communication with a gate  85  to a mold cavity  80 , 
         [0007]    the distal tip of the nozzle  50  being comprised of a highly heat conductive insert  55  and an insulation cap  64  that is substantially less heat conductive than the insert  55 , mounted coaxially within the nozzle channel  54  in nested contact with each other, 
         [0008]    the highly heat conductive insert  55  and the insulation cap  60  each having a downstream end portion containing a fluid exit aperture  55   e ,  64  that are aligned with each other enabling flow of injection fluid  32  through the nozzle channel  54  downstream into the mold cavity  80 , 
         [0009]    the downstream end portion of the insulation cap  60  being disposed between the gate  85  and the downstream end portion of the highly heat conductive insert  55  forming a fluid seal (S) around the gate  85 , 
         [0010]    a valve pin  90  interconnected to an actuator  941  adapted for controllably driven reciprocal movement of the valve pin coaxially A through the nozzle flow channel  54 , the valve pin  90  having a distal end portion  90   de  having a downstream-most circumferential surface  99  complementary to an axially interior surface  76   s  of the gate  85  and a downstream surface portion  92 ,  97  immediately upstream of the downstream-most circumferential surface  99 , the downstream surface portion  92 ,  97  having a gap enabling circumferential surface  92  around the circumference of a bulbous portion  90   p  of the valve pin, 
         [0011]    the actuator  941  being adapted to controllably drive the distal end portion of the valve pin  90   de  along a drive path extending between one or more upstream positions (P 1 , P 2 , P 3 ) where the injection fluid flows through the gate  85  and a downstream gate closed position P 4  where the distal end portion  90   de  of the valve pin  90  mates with the axially interior surface  76   s  of the gate  85  to stop flow of injection fluid through the gate, 
         [0012]    Preferably, when the valve pin  90  is in the gate closed position (P 4 ), an axially interior surface  64   s  of the fluid exit aperture  64  of the insulation cap  60  surrounds the gap enabling circumferential surface  92  of the valve pin forming a spatial gap  60   g  immediately upstream of the gate  85  between the interior surface  64   s  of the fluid exit aperture  64  of the insulation cap  60  and the gap enabling circumferential surface  92  of the valve pin  90 . 
         [0013]    The actuator can be interconnected to a controller ( 16 ) that controllably instructs the actuator ( 941 ) to drive the distal end portion ( 90   d ,  97 ) of the valve pin continuously upstream starting from the gate closed position (P 4 ) at one or more intermediate upstream velocities that are less than a predetermined high velocity and to subsequently further drive the valve pin upstream at the predetermined high velocity. 
         [0014]    Preferably the actuator comprises a hydraulically driven or pneumatically driven actuator. The actuator can comprise an electrically powered motor. 
         [0015]    The spatial gap is typically adapted to receive injection fluid that is forced upstream from the gate when the valve pin is moved downstream toward the gate closed position. 
         [0016]    The axially interior surface of the gate typically comprises a surface of the mold. 
         [0017]    The nozzle channel can have an axially interior surface disposed upstream of the fluid exit apertures that is complementary to and slidably engages with the gap enabling circumferential surface of the valve pin to align the axis of the valve pin with the gate during downstream movement of the valve pin toward the gate closed position. 
         [0018]    An axially inner surface of an upstream end portion of the insulation cap is typically engaged against an axially outer surface of a downstream end of the insert, the upstream end portion of the insulation cap being compressed between the insert and an axially inner surface of the distal tip of the nozzle to seal flow of the injection fluid to within the nozzle channel. 
         [0019]    The distal end portion of the valve pin is preferably configured such that flow of injection fluid through the gate is restricted at one or more positions of the valve pin that are intermediate the gate closed position and a fully upstream gate open position at which flow of the injection fluid is unrestricted. 
         [0020]    In another aspect of the invention there is provided a method of performing an injection molding cycle comprising injecting the injection fluid ( 32 ) from an injection molding machine ( 20 ) into the manifold channel ( 35 ) of the apparatus ( 10 ) described immediately above and using the apparatus ( 10 ) to inject the injection fluid ( 32 ) into the mold cavity ( 80 ) during the course of an injection molding cycle. 
         [0021]    In another aspect of the invention there is provided with reference to  FIGS. 2-5 , an injection molding apparatus ( 10 ) comprising: 
         [0022]    a manifold ( 30 ) having a manifold channel ( 35 ) receiving an injection fluid ( 32 ), 
         [0023]    a nozzle ( 50 ) having a nozzle channel ( 54 ) receiving injection fluid ( 32 ) from the manifold channel ( 35 ), the nozzle having a distal tip in fluid communication with a gate ( 85 ) to a cavity ( 80 ) of a mold ( 88 ), 
         [0024]    the distal tip being comprised of a highly heat conductive insert ( 55 ) mounted in contact with an insulation cap ( 60 ) that is mounted between the insert and the gate, the insulation cap being substantially less heat conductive than the insert, 
         [0025]    the insulation cap ( 60 ) forming a fluid seal (S) around the gate ( 85 ) such that a fluid sealed flow channel ( 54 ) is formed extending from an upstream end of the nozzle ( 50 ) to the gate ( 85 ), 
         [0026]    a valve pin ( 90 ) having a distal end portion ( 90   de ) having a circumferential surface ( 97 ,  99 ), and a distal tip end ( 90   d ), 
         [0027]    an actuator ( 941 ) drivably interconnected to the valve pin adapted to drive the valve pin ( 90 ) along a drive path extending between a gate closed position (P 4 ), one or more intermediate upstream positions (P 3 ) where the distal tip end of the valve pin restricts (FG) flow ( 32   r ) of the injection fluid through the gate ( 85 ) and a third position (P 1 , P 2 ) upstream of the intermediate upstream positions (P 3 ) where the injection fluid ( 32 ) flows freely through the gate without restriction, 
         [0028]    wherein when the valve pin ( 90 ) is in the gate closed position (P 4 ), the distal tip end ( 90   d ) of the valve pin ( 90 ) seals the gate ( 85 ) and a downstream circumferential surface ( 97 ,  99 ) of the distal end portion ( 90   de ) of the valve pin mates with a complementary axially interior surface ( 76   s ,  88   cs ) of the gate ( 85 ), and, 
         [0000]    wherein the insulation cap ( 60 ) is configured to form a circumferential gap ( 60   g ) around an upstream circumferential surface ( 92 ) of a bulbous protrusion ( 90   p ) of the distal end portion ( 90   de ) of the valve pin that is disposed immediately upstream of the complementary axially interior surface ( 76   s ,  88   cs ) of the gate ( 85 ) when the valve pin is in the gate closed position (P 4 ). 
         [0029]    In such an apparatus as just described, the complementary internal surface of the gate can comprise a surface of the mold ( 88 ). 
         [0030]    The upstream circumferential surface of the distal end portion of the valve pin preferably slidably engages with an axially interior surface of the nozzle flow channel to align the axis of the pin with the gate during downstream movement of the pin toward the gate closed position. 
         [0031]    The actuator can comprise a hydraulically driven or pneumatically driven actuator or an electrically powered motor. 
         [0032]    The actuator is typically interconnected to a controller that controllably instructs the actuator to drive the distal end portion of the valve pin continuously upstream starting from the gate closed position at one or more intermediate upstream velocities that are less than a predetermined high velocity and to subsequently further drive the valve pin upstream at the predetermined high velocity. 
         [0033]    In another aspect of the invention there is provided a method of performing an injection molding cycle comprising injecting the injection fluid from an injection molding machine ( 10 ) into the manifold channel of the apparatus described above and using such an apparatus to inject the injection fluid into the mold cavity during the course of the injection molding cycle. 
         [0034]    In another aspect of the invention there is provided an injection molding system an injection molding system comprising: 
         [0035]    a manifold having a melt channel receiving a melt stream of injection fluid, 
         [0036]    a nozzle having a melt channel receiving injection fluid from the manifold melt channel, the nozzle having a distal tip in fluid communication with a gate to a cavity of a mold, 
         [0037]    the distal tip being comprised of a highly heat conductive insert mounted in contact with an insulation cap that is mounted in compressed contact with the gate, the insulation cap being substantially less heat conductive than the insert, 
         [0038]    the insulation cap forming a fluid seal around the gate such that a fluid sealed flow channel is formed extending from an upstream end of the nozzle to the gate, 
         [0039]    a valve pin having a circumferential surface and an axis mounted and adapted for controllably driven reciprocal movement of the valve pin through the flow channel from a gate closed position to selectable upstream positions, the valve pin having a distal end portion having a circumferential surface geometry that conforms to a selected internal surface geometry of the flow channel and gate and having a distal tip end that is flat, 
         [0040]    an actuator drivably interconnected to the valve pin adapted to drive the distal tip end along a drive path extending between the gate closed position, one or more intermediate upstream positions where the distal tip end of the valve pin restricts flow of the injection fluid through the gate and a third position upstream of the intermediate upstream positions where the injection fluid flows freely through the gate without restriction, 
         [0041]    wherein when the valve pin is in the gate closed position, the distal tip end seals the gate and a secondary portion of the circumferential surface of the valve pin that is disposed immediately upstream of the distal tip end is in contact with a first internal surface of the flow channel surrounding the gate that is immediately downstream of the insulation cap. 
         [0042]    The insulation cap is typically configured to form a circumferential gap around a portion of the circumferential surface of the pin that is disposed immediately upstream of the first internal surface of the flow channel when the secondary portion of circumferential surface of the valve pin is contact with the first internal surface of the flow channel. 
         [0043]    The first internal channel surface surrounding the gate preferably comprises a surface of the mold. 
         [0044]    The pin preferably has a tertiary portion of its circumferential surface that is upstream of the secondary portion that slidably engages with a second internal surface of the flow channel to align the axis of the pin with the gate during downstream movement of the pin toward the gate closed position. 
         [0045]    The second internal surface of the flow channel is typically disposed immediately upstream of the insulation cap, the insulation cap being configured to form a circumferential gap around a portion of the circumferential surface of the pin that is disposed immediately upstream of the first internal surface of the flow channel when the secondary portion of the circumferential surface of the valve pin is contact with the first internal surface of the flow channel. 
         [0046]    An inner surface of an upstream end portion of the insulation cap is preferably engaged against an outer surface of a downstream end of the insert, the upstream end portion of the insulation cap being compressed between the insert and an inner surface of the distal tip of the nozzle to seal flow of the injection fluid to within the flow channel. 
         [0047]    The distal tip end of the valve pin can have an outer circumferential edge that is sharpened. Alternatively the distal tip end of the valve pin can have an outer circumferential edge that is rounded or curved. 
         [0048]    The actuator can be hydraulic, pneumatic or electrically powered. 
         [0049]    The actuator is preferably driven by a valve system that is controllably adjustable between a start position that positions the distal tip end of the valve pin in the gate closed position, one or more intermediate drive rate positions that drive the valve pin upstream from the gate closed position through one or more intermediate upstream positions at one or more corresponding intermediate velocities and a high drive rate position that drives the valve pin at a high velocity that is higher than the intermediate velocities. 
         [0050]    In another aspect of the invention there is provided a method of performing an injection molding cycle comprising operating an injection molding system having a controllably adjustable actuator as described immediately above by: 
         [0051]    preselecting a length of travel between the gate closed position and one or more selected intermediate upstream positions, 
         [0052]    beginning an injection cycle with the tip end of the valve pin in the gate closed position and the valve system in the start position, 
         [0053]    adjusting the valve system to operate at one or more of the intermediate drive rate positions to drive the tip end of the valve pin continuously upstream from the gate closed position to the one or more selected intermediate upstream positions, 
         [0054]    sensing the position of the valve pin to determine when the tip end of the valve pin has reached the one or more selected intermediate upstream positions, and, 
         [0055]    adjusting the valve system to operate at a selected high drive rate position to drive the distal tip end of the valve pin continuously upstream at a corresponding high velocity when the tip end of the valve pin has been determined in the step of sensing to have reached the selected one or more intermediate upstream positions. 
         [0056]    In another aspect of the invention there is provided an injection molding system as described above wherein the actuator is driven by a valve system that is controllably adjustable between a first position that positions the distal tip end of the valve pin in a selected fully upstream position, one or more intermediate downstream drive rate positions that drive the valve pin downstream from the fully upstream position toward the gate to one or more intermediate downstream positions at one or more intermediate downstream velocities and one or more closure drive rate positions that drives the valve pin at one or more low velocities that are lower than the intermediate downstream velocities. 
         [0057]    In another aspect of the invention there is provided a method of performing an injection molding cycle comprising operating an injection molding system as described immediately above by: 
         [0058]    preselecting a length of travel between the selected fully upstream position and the one or more selected intermediate downstream positions, 
         [0059]    beginning a downstream drive portion of an injection cycle with the tip end of the valve pin in the selected fully upstream position and the valve system in the first position, 
         [0060]    adjusting the valve system to operate at one or more of the intermediate drive rate positions to drive the tip end of the valve pin continuously downstream from the selected fully upstream position toward the one or more selected intermediate downstream positions, 
         [0061]    sensing the position of the valve pin to determine when the tip end of the valve pin has reached one or more selected intermediate downstream positions, and, 
         [0062]    adjusting the valve system to operate at one or more selected closure rate positions to drive the distal tip end of the valve pin continuously downstream at a corresponding low velocity when the tip end of the valve pin has been determined in the step of sensing to have reached the selected one or more intermediate downstream positions. 
         [0063]    In another aspect of the invention there is provided an injection molding system comprising: 
         [0064]    a manifold having a melt channel receiving a melt stream of injection fluid, 
         [0065]    a nozzle having a melt channel receiving injection fluid from the manifold melt channel, the nozzle having a distal tip in fluid communication with a gate to a cavity of a mold, 
         [0066]    the distal tip being comprised of a highly heat conductive insert mounted in contact with the gate, 
         [0067]    a valve pin having a circumferential surface and an axis mounted and adapted for controllably driven reciprocal movement of the valve pin through the flow channel from a gate closed position to selectable upstream positions, the valve pin having a distal end portion having a circumferential surface geometry that conforms to a selected internal surface geometry of the flow channel and gate and having a distal tip end that is flat, 
         [0068]    an actuator drivably interconnected to the valve pin adapted to drive the distal tip end along a drive path extending between the gate closed position, one or more intermediate upstream positions where the distal tip end of the valve pin restricts flow of the injection fluid through the gate and a third position upstream of the intermediate upstream positions where the injection fluid flows freely through the gate without restriction, 
         [0069]    wherein when the valve pin is in the gate closed position, the distal tip end seals the gate and a secondary portion of the circumferential surface of the valve pin that is disposed immediately upstream of the distal tip end is in contact with a first internal surface of the flow channel surrounding the gate that is immediately upstream of the gate. 
         [0070]    In such an apparatus the first internal surface of the flow channel can comprise a surface of the mold. 
         [0071]    In such an apparatus the pin can have a tertiary portion of its circumferential surface that is upstream of the secondary portion that slidably engages with a second internal surface of the flow channel to align the axis of the pin with the gate during downstream movement of the pin toward the gate closed position. 
         [0072]    In such an apparatus the distal tip end of the valve pin can have an outer circumferential edge that is sharpened. Alternatively the distal tip end of the valve pin can have an outer circumferential edge that is rounded or curved. 
         [0073]    The actuator can be hydraulic, pneumatic or electrically powered. 
         [0074]    In such an apparatus the actuator is driven by a valve system that is controllably adjustable between a start position that positions the distal tip end of the valve pin in the gate closed position, one or more intermediate drive rate positions that drive the valve pin upstream from the gate closed position through one or more intermediate upstream positions at one or more corresponding intermediate velocities and a high drive rate position that drives the valve pin at a high velocity that is higher than the intermediate velocities. 
         [0075]    In another aspect of the invention there is provided, a method of performing an injection molding cycle comprising operating the injection molding system described immediately above by: 
         [0076]    preselecting a length of travel between the gate closed position and one or more selected intermediate upstream positions, 
         [0077]    beginning an injection cycle with the tip end of the valve pin in the gate closed position and the valve system in the start position, 
         [0078]    adjusting the valve system to operate at one or more of the intermediate drive rate positions to drive the tip end of the valve pin continuously upstream from the gate closed position to the one or more selected intermediate upstream positions, 
         [0079]    sensing the position of the valve pin to determine when the tip end of the valve pin has reached the one or more selected intermediate upstream positions, and, 
         [0080]    adjusting the valve system to operate at a selected high drive rate position to drive the distal tip end of the valve pin continuously upstream at a corresponding high velocity when the tip end of the valve pin has been determined in the step of sensing to have reached the selected one or more intermediate upstream positions. 
         [0081]    In such an apparatus the actuator can be driven by a valve system that is controllably adjustable between a first position that positions the distal tip end of the valve pin in a selected fully upstream position, one or more intermediate downstream drive rate positions that drive the valve pin downstream from the fully upstream position toward the gate to one or more intermediate downstream positions at one or more intermediate downstream velocities and one or more closure drive rate positions that drives the valve pin at one or more low velocities that are lower than the intermediate downstream velocities. 
         [0082]    In another aspect of the invention there is provided a method of performing an injection molding cycle comprising operating an injection molding system as described immediately above by: 
         [0083]    preselecting a length of travel between the selected fully upstream position and the one or more selected intermediate downstream positions, 
         [0084]    beginning a downstream drive portion of an injection cycle with the tip end of the valve pin in the selected fully upstream position and the valve system in the first position, 
         [0085]    adjusting the valve system to operate at one or more of the intermediate drive rate positions to drive the tip end of the valve pin continuously downstream from the selected fully upstream position toward the one or more selected intermediate downstream positions, 
         [0086]    sensing the position of the valve pin to determine when the tip end of the valve pin has reached one or more selected intermediate downstream positions, and, 
         [0087]    adjusting the valve system to operate at one or more selected closure rate positions to drive the distal tip end of the valve pin continuously downstream at a corresponding low velocity when the tip end of the valve pin has been determined in the step of sensing to have reached the selected one or more intermediate downstream positions. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0088]    The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which: 
           [0089]      FIG. 1  is a side cross-sectional view of a prior art valve configuration having an insert IN and an insulation cap and a valve pin configuration where the distal tip end portion of the valve pin, when driven into the gate closed position as shown provides no relief or escape from the high pressure of injection fluid that is being forced into the mold cavity during the course of movement of the valve pin from an upstream position downstream into a gate closed position. 
           [0090]      FIG. 2  is a side cross-sectional view of an embodiment of the invention showing a valve pin during the course of an injection cycle disposed at an upstream position within a flow channel within a nozzle where the gate to the mold is not obstructed by the pin and fluid injection material flows freely through the gate. 
           [0091]      FIG. 3  is a view similar to  FIG. 1  at a later time in the injection cycle where the valve pin has been driven downstream slightly to a position where the outer circumferential surface of the valve pin has come closer in distance to an inner surface of the flow channel. 
           [0092]      FIG. 4  is a view similar to  FIGS. 1, 2  at yet a later time in the injection cycle where the valve pin has been driven downstream to a position where a selected widened and configured portion of the outer circumferential surface of the pin has almost come into contact with a complementary portion of an inner guide surface  55   gs  of the flow channel such that the axis of the pin is aligned with the gate to the mold and the distal tip end of the pin is guided in alignment toward the gate. 
           [0093]      FIG. 5  is a view similar to  FIGS. 2-4  at yet a later time in the injection cycle where the valve pin has been driven downstream to a gate closed position with the distal tip end of the valve pin fully inserted within and closing a complementary geometrically configured gate aperture. 
       
    
    
     DETAILED DESCRIPTION 
       [0094]      FIG. 1  shows a prior art valve configuration having a nozzle insert IN and an insulation cap IC with a valve pin having a configuration where the distal tip end portion of the valve pin, when driven into the gate closed position as shown provides no relief or escape from the high pressure of injection fluid that is being forced into the mold cavity during the course of movement of the valve pin from an upstream position downstream into a gate closed position. 
         [0095]      FIG. 2  shows one system embodiment  10  of the invention comprised of an injection machine  20  that feeds meltable injection material that is converted from solid form into molten or liquid flowing material form within the barrel (not shown) of the machine  20  by a screw (not shown) that drives the molten material  32  downstream under a controlled pressure into the fluid distribution channels  35  of a hotrunner or manifold  30 . The molten fluid  32  is driven from the manifold channel  35  into the upstream end  52 ,  FIGS. 3, 4  of a central flow passage or channel  54  of a nozzle  50 . 
         [0096]    The nozzle  50  is mounted within an aperture  83  provided within the mold body  88  or an intermediate plate that is mounted to the mold plate  88 . The melt material  32  further flows downstream under pressure through a continuous flow channel  54 ,  54   a ,  64 ,  74  that extends from the upstream end  52  of the nozzle to a gate  85  of a mold cavity  80 , the continuous flow channel  54 ,  54   a ,  64 ,  74  being collectively comprised of the upper nozzle channel  54 ,  FIGS. 3, 4 , that sealably communicates with downstream channel  54   a  that is disposed within a nozzle insert  55  which further communicates with a channel  64  that is formed within an insulation cap  60  that in turn sealably communicates with a downstream channel  74  formed within the body of the mold  88 , the channel  74  communicating at its downstream end with the gate  85  to the cavity  80  of the mold  88 . 
         [0097]    As shown in  FIGS. 2-5 , the nozzle  50  itself is comprised of an outermost cylindrical nozzle tube or body  53  having a central flow channel  54 , a cylindrical nozzle tip  56  that is typically screwably engaged concentrically within the downstream distal end of the outer body  53  of the nozzle  50 , a cylindrical nozzle insert  55  having a flow channel  54   a  that is concentrically mounted within the interior circumference of the tip  56  and a cylindical insulation cap  60  having a flow bore or exit aperture  64  that is concentrically mounted between the axially outer circumferential surface of the insert  55  and the distal-most portion of the axially inner circumferential surface of the nozzle tip  56 . 
         [0098]    The system includes a valve pin  90  interconnected at an upstream end to an actuator  941  in a conventional manner (not shown) as described and shown in, for example, U.S. Patent Application Publication No. 2012/0248644 or U.S. Patent Application Publication No. 2012/0248652 such that the actuator  941  and pin  90  move reciprocally upstream and downstream A in unison along an axial path A through the flow channel  54 ,  54   a ,  64 ,  74 . The actuator  941  is interconnected to a controller  16  that contains an algorithm that controls the upstream-downstream velocity of movement of the pin  90  and actuator  941  along axis A between a fully gate closed,  FIG. 4 , and a fully upstream position. The actuator  941  can comprise a fluid driven mechanism such as a hydraulically or pneumatically driven actuator as described in for example U.S. Pat. Nos. 5,894,025, 6,464,909, 6,585,505, 8,016,581, 7,597,828 the disclosures of all of which are incorporated herein by reference as if fully set forth herein. Alternatively the actuator  941  can comprise an electrically driven motor, the shaft of which is interconnected to the valve pin as disclosed for example in U.S. Pat. No. 6,194,122 the disclosure of which is incorporated herein by reference as if fully set forth herein. The controller  16  can be adapted to controllably drive any of the hydraulic, pneumatic or electric motor actuators referenced above in order to drive the valve pin along any path of travel during the course of an injection cycle according any predetermined program, algorithm or protocol. 
         [0099]    The outer circumferential surface  57  of the nozzle tip  56  forms a fluid seal around the gate  85  by compressed engagement with an inner circumferential surface  86  of the mold  88  thus sealing injection fluid within the central flow channel  54 ,  54   a ,  64 ,  74  and preventing injection fluid from seeping into the cavity or aperture  83  in which the nozzle  50  is mounted. Additionally, the outer surface  60   s  of the insulation cap  60  is in compressed contact with the axially inner surface  81   s  of the receiving or mounting aperture  81  forming a fluid seal S around the gate  85  that seals and prevents injection fluid  32  from seeping into the cavity or aperture  83  in which the nozzle  50  is mounted. 
         [0100]    The nozzle body  53 ,  FIGS. 2-5 , is typically heated to an elevated temperature so as to maintain the injection fluid material at an elevated ready flow facilitated temperature. The insert  55  is typically mounted concentrically within the nozzle tip  56  in thermal communication with the nozzle body  53  and tip  56  and is thus in turn heated and is preferably comprised of a highly heat conductive material so as to remain heated together with the nozzle body  53  and tip  56  to maintain the injection fluid material flowing through channel  54 ,  54   a ,  64 ,  74  at a high flow ready temperature at or near the entry to the gate  85 . 
         [0101]    The insulation cap  60 ,  FIGS. 2-5 , is comprised of a non heat conductive or heat insulative material. The mold body  88  is cooled with water during an injection cycle and is maintained at a relatively low or cooled temperature relative to the very high temperature of the nozzle  50  and its associated components  53 ,  55 ,  56 . The insulation cap  60  is mounted immediately downstream of the highly conductive insert  55  between the insert  55  and any opposing interior surface of the mold body  88  which is cool or cooled relative to the very high temperature of the nozzle  50  and its components  53 ,  55 ,  56 . The insulation cap  60  thus insulates heat transfer or loss between the nozzle  50  and the mold  88 . 
         [0102]    As shown,  FIGS. 2-5 , the geometry or configuration of the insulation cap  60 , the insert  55  and the receiving cavity or aperture  81  of the mold  88  within which the cap  60  is mounted are all adapted and configured such that an interior surface  63  of the cap  60  receives and engages a major portion of the exterior circumferential surface  55   es  of the highly conductive insert  55  thus facilitating and effecting prevention of heat transfer or thermal insulation between the insert  55  and the mold  88 . 
         [0103]      FIG. 2  shows the system at a point in time in an injection cycle where the valve pin  90  is disposed in an upstream, gate open position where injection fluid flow through the channel  54 ,  54   a ,  64 ,  74  is not restricted by the distance between an exterior circumferential surface of the pin  90  and an interior surface of the channel  54 ,  54   a ,  64 ,  74 . 
         [0104]      FIG. 3  shows the system at a point in time in an injection cycle where the pin  90  has moved downstream nearer the gate  85  relative to the position of the pin  90  in  FIG. 2 . As shown in  FIGS. 2-5 , the pin  90  has a distally disposed bulbous protrusion  90   p  that has a distally disposed portion of its exterior circumferential surface  92  that is formed and configured to be complementary in geometry, diameter and the like to the geometry, diameter and configuration of a complementary axially interior surface  55   gs  of the insert  55 , the surface  55   gs  being formed to be complementary to the surface  92  and to slidably receive and engage surface  92  as the pin  90  axially moves A such that the axis A of the pin is guided in its movement in alignment with the gate  85  and with the flow channel  54 ,  54   a ,  64 ,  74  generally.  FIG. 4  shows the system  10  at a point in time in an injection cycle where the pin surface  92  is immediately upstream of being received by and slidably engaging against the guide surface  55   gs  of the insert. In this pin position P 3 , a small gap FG is formed between the axially interior surface  55   s ,  FIG. 4 , where the rate of flow of injection fluid  32   r  is reduced relative to the rate of flow when the pin is in the positions P 1  and P 2  of  FIGS. 2, 3  respectively. Such a reduced flow rate  32   r  occurs over some length of pin travel PT 1  and PT 2  when the circumferential surface  92  is closely adjacent, either upstream (PT 1 ) or downstream (PT 2 ) to or of the guide surface  55   gs . When the circumferential surface  92  actually mates with the guide surface  55   gs , the flow of injection fluid is essentially stopped. 
         [0105]      FIG. 5  shows the system and the position of the pin P 4  at a point in time when the pin  90  has been driven to it furthest downstream position whereby the gate  85  to the mold cavity  80  has been closed and flow of molten injection material through the channel  54 ,  54   a ,  64 ,  74  is stopped. As shown in  FIGS. 2, 3, 4  the mold body  88  is formed having a receiving cavity or channel  74  that has an interior surface  88   cs  that is complementary in geometry and configuration to the preselected geometry and configuration of a distally disposed end portion of the exterior circumferential surface  97  of the pin  90 . The surface  88   cs  is configured such that when the pin  90  is driven to its furthest downstream position shown in  FIG. 5 , the complementary surface  97  of the pin engages with surface  88   cs  to force all injection fluid material that resides in the distal portion  74  of the flow channel through the gate  85 . 
         [0106]    As shown in  FIGS. 2, 3, 4, 5  the distal-most portion  90   d  of the pin  90  has a cylindrically shaped outer circumferential surface  99  that is complementary to an inner surface  76   s  of the distal-most space  76  that is immediately downstream of the flow channel  54 ,  54   a ,  64 ,  74  such that when the pin  90  is driven to its fully gate closed position as shown in  FIG. 4 , the circumferential surface  99  of portion  90   d  will slidably engage against surface  76   s  and the distal tip end surface  90   dte  of the pin  90  will force all injection fluid material that resides in the distal-most portion  76  of the flow channel through the gate  85 . The distal-most edges or corners  90   c  of the distal-most portion  90   d  of the pin  90  are preferably sharpened such that the outer surfaces of portion  90   d  that mate to form the edges or corners  90   c  are either flat or concave. Alternatively, the bottom surface  90   dte  of pin  90  can be convex or have a slight outward radius rendering the corners  90   c  rounded or curved. 
         [0107]    The insulation cap  60  can be adapted, formed or configured to form a sealed or enclosed circumferential gap or space  60   g  that surrounds the circumferential surface of the valve pin that is immediately upstream of the gate  95 . Such a space  60   g  serves to receive upstream backflow of injection fluid that is forced into space  76  that does not readily flow through gate  85  during the course of driven downstream movement of the pin  90  into a fully gate closed position and the movement of tip end member  90   d  into space  76 , the circumferential gap or space  60   g  also serving to relieve excess pressure in the injection fluid in the immediate area of the gate  85  during the course of such closure of the pin  90 , such relief of excess pressure minimizing or preventing the occurrence of a visual defect or artifact in the final cooled part produced within the cavity  80 . As shown, the gap  60   g  is formed between the axially interior surface  64   s  and the circumferential surface  92  of the bulbous protrusion portion  92   p  of the valve pin  90 . 
         [0108]    As described in detail in International Application Publication No. WO2012/074879, U.S. Patent Application Publication No. 2012/0248644, International Application Publication No. 2012/087491 and U.S. Patent Application Publication No. 2012/0248652, the disclosures of which are incorporated herein by reference, the valve pin  90  is interconnected to an actuator  941 , the operation of which is controlled by an electronic controller  16  that contains an algorithm that controllably drives the valve pin  90  to selectable axial positions or at selectable velocities along the axis A of the flow channel  54 ,  54   a ,  64 ,  74 . The system can include a position sensor  951  that detects axial position of the pin or the actuator and sends the position signal to the controller  16  which uses the position signal to cause the pin  90  to be driven to selected positions or at preselected velocities either upstream or downstream depending on the detected position of the pin  90 . As described in International Application Publication No. WO2012/074879 and U.S. Patent Application Publication No. 2012/0248644, the velocity of the pin is typically withdrawn beginning from a gate closed position to a predetermined upstream position at a relatively low velocity that prevents fluid injection material from flowing through the gate  85  into the cavity  80  at a rate that will result in a visual defect, vestige or artifact occurring in the part that is ultimately produced in the mold cavity  80 . Also as described in International Application Publication No. WO2012/074879 and U.S. Patent Application Publication No. 2012/0248644, the algorithm can be programmed to cause the valve pin  90  to be withdrawn upstream at a high velocity that is higher than the initial lower velocity (typically the maximum velocity at which the hydraulic, pneumatic or electric motor drive system is capable of driving the pin) when the axial position of the pin  90  or actuator  941  has been determined by the position sensor  951  to have reached an intermediate upstream position at which the valve pin  90  does not restrict the flow of injection fluid through the gate  85 . Most preferably the valve pin  90  is driven continuously upstream from the gate closed position (shown in  FIG. 5 ) to a fully upstream gate open position during the upstream withdrawal portion of an injection cycle. 
         [0109]    As described in International Application Publication No. WO2012/074879 and U.S. Patent Application Publication No. 2012/0248644, the valve pin  90  or actuator  941  can also be controllably driven from an upstream position to the gate closed position,  FIG. 5 , at variably selectable velocities. Typically, the pin  90  or actuator  941  is driven from a fully upstream position to a preselected intermediate downstream position at a relatively high velocity (typically maximum velocity for the drive system) and then, when detected to be at the selected intermediate downstream position, driven at a lower selected velocity (lower than the high velocity) from the preselected intermediate downstream position to the gate closed position, the lower velocity being preselected to minimize or prevent any visual defect, vestige or artifact occurring in the part that is ultimately produced in the mold cavity  80 . Most preferably the valve pin  90  or actuator  941  is driven continuously downstream during the downstream drive portion of an injection cycle. 
         [0110]    As described in International Application No. 2012/087491 and U.S. Patent Application Publication No. 2012/0248652, the valve pin  90  and actuator  941  can alternatively be driven upstream or downstream at variably selectable velocities based on the elapse or occurrence of a predetermined amount of time without reliance on detection of axial position of the pin  90  or actuator  941  by a position sensor. As in the previously described embodiments, the valve pin  90  or actuator  941  is typically withdrawn upstream beginning from a fully start or gate closed position ( FIG. 5 ) for a predetermined amount of time at a relatively low velocity that prevents fluid injection material from flowing through the gate  85  into the cavity  80  at a rate that will result in a visual defect, vestige or artifact occurring in the part that is ultimately produced in the mold cavity  80 . The predetermined amount of upstream withdrawal time at the selected low velocity results in the pin  90  or actuator  941  being withdrawn to some predetermined intermediate upstream position that is determined by trial and error. The predetermined intermediate upstream position is preferably a position at which the valve pin  90  does not restrict the flow of injection fluid through the gate  85 . upon expiration of the predetermined amount of time at which the pin is withdrawn at the initial low velocity, the algorithm is typically programmed to cause the valve pin  90  or actuator  941  to be withdrawn upstream at a high velocity that is higher than the initial lower velocity (typically the maximum velocity at which the hydraulic, pneumatic or electric motor drive system is capable of driving the pin). Most preferably the valve pin  90  is driven continuously upstream from the gate closed position (shown in  FIG. 4 ) to a fully upstream gate open position during the upstream withdrawal portion of an injection cycle. 
         [0111]    As described in International Application No. 2012/087491 and U.S. Patent Application Publication No. 2012/0248652, the valve pin  90  and actuator  941  can alternatively be controllably driven from an upstream position to the gate closed position,  FIG. 5 , at variably selectable velocities based on preselected times. Typically, the pin  90  or actuator  941  is driven from a fully upstream position at a relatively high velocity (typically maximum velocity for the drive system) for a preselected amount of time that results in the pin  90  being driven to an intermediate downstream position and then, upon expiration of the preselected amount of high velocity downstream drive time, the valve pin  90  or actuator  941  is driven at a lower selected velocity (lower than the high velocity) from the intermediate downstream position to the gate closed position, the lower velocity being preselected to minimize or prevent any visual defect, vestige or artifact occurring in the part that is ultimately produced in the mold cavity  80 . Most preferably the valve pin  90  or actuator  941  is driven continuously downstream during such a downstream drive portion of an injection cycle.