Abstract:
An injection molding apparatus which includes a check valve assembly mounted at the forward end of a feed-screw, the valve assembly having forward and rearward valve seat surfaces which co-act in a first position to allow a plasticized polymeric material to enter and flow through the valve into an injection chamber and which co-act in a second position to stop any additional material from entering the valve assembly. The second valve position is effected by a feed-screw injection stroke which generates a back pressure to close the valve, the back pressure moving a check ring of the valve assembly into a position to block entry into the valve. Part of the valve seat surfaces are covered with a plurality of ceramic disks and other valve seat surfaces are covered with a metal alloy which effectively increases the abrasion resistance of the valve seat surfaces and thus also increases the wear service life of the check valve assembly. Other wear surfaces of the valve assembly may also be coated for abrasion resistance.

Description:
RELATED US APPLICATIONS 
   This is a continuation-in-part of Ser. No. 10/452,421, filed Jun. 2, 2003, Pub No. U.S. 2003/0211198 A1, Pub Date Nov. 13, 2003, now abandoned which is a continuation-in-part of Ser. No. 09/943,152, filed Aug. 30, 2001, now abandoned. 

   FIELD OF THE INVENTION 
   This invention relates generally to the art of injection molding apparatus and, more particularly, to an improvement in injection molding apparatus check valve assemblies as applied to restrict back-flow of a plasticized polymeric material during an injection stroke of the apparatus. The specific improvement comprises adhesively attaching abrasion-resistant disks within recesses extending into friction wear surfaces of an injection molding check valve. surfaces. 
   BACKGROUND OF THE INVENTION 
   Injection molding of plasticized polymeric materials including plastic and/or elastomeric type materials has been known and practiced for a long time. These type of apparatus are conventionally associated with various molding machines which are adapted for receiving the plasticized polymer and forming it into many useful parts and/or products. 
   Injection molding apparatus of the type alluded to are generally comprised of a feed-screw or auger member rotatably carried within a substantially cylindrical barrel, the screw effectively moving and plasticizing the polymeric material throughout the length of the barrel towards an exit end where it is forcefully injected into a molding machine for forming and curing of the material into the desired end product. At an exit end of the feed-screw there is conventionally mounted a check valve assembly which is designed to meter out the proper amount of plasticized material by a pressure reactive motion of the valve to effectively shut off the supply of material and to thereafter force the desired volume of plasticized polymer out of an exit nozzle and into the mold cavity of the molding machine. 
   Many improvements in this art have been suggested and applied to the injection molding apparatus and these, to an improved configuration of the feed-screw member and/or to the check valve assembly to gain greater efficiency in the injection operation by shortening the injection cycle period. Obviously, a shorter cycle period of the injection molding apparatus will also result in an increase in the number of parts which may be produced inasmuch as the molding machines associated therewith may also be configured to accept and form more individual parts. 
   These improvements in the injection molding apparatus have fairly coincided with advances in the polymer science and technology which has provided improved material chemistry. The improvements, however, have not been without problems as there is now a noticeable increase in wear of the various member elements which comprise the injection molding apparatus. For example, it has been determined that no natural lubricants are available in many of the polymeric materials and this lack of lubrication increases the friction and therefore also the heat generated in plasticizing and injecting the material. Furthermore, it is not possible to add a lubricating material to the process as these tend to contaminate the polymer and this affects the quality of the finished molded product. 
   In view of the above, friction wear of critical working elements of the injection molding apparatus is a major and continuing problem in the industry as these must be replaced at regular and, in some instances, very short intervals. 
   It is, of course, generally well-known and recognized by those knowledgeable in this art that the various working elements of the injection molding apparatus are comprised of very expensive tool and/or alloy steels, and this, because of the exceptional wear that these elements experience in this type of process. Thus, the very short service lifetimes of these elements will naturally also effect an increase in the cost of the molded parts being produced. 
   The following prior art patents fairly represent what has been done in attempts to improve the injection molding apparatus: U.S. Pat. Nos. 3,698,694; 4,106,113; 4,105,147; 4,472,058; and 4,988,281. Further, U.S. Pat. No. 3,209,408 addresses the friction wear problem by providing a ball-bearing configured check valve assembly. Such type ball-bearing configurations-are also evident in some of the above-listed prior art patents. In addition, U.S. Pat. No. 4,530,605 attempts to alleviate part of this problem by providing a rapid take-down configuration for a check valve assembly such that when worn parts need to be replaced this may be done quickly and efficiently with the least amount of down-time. From this it should be apparent that the friction wear problem of critical elements of an injection molding apparatus still exists and this, irrespective of the various advances in the art. 
   Our prior U.S. Pat. No. 5,167,971 helped to solve the problem by reducing the amount of wear on the various wear surfaces of the valve assembly, and in our prior application Ser. No. 09/943,152, abrasion resistant ceramic layers were adhesively attached to the wear surfaces, however further modifications were found to be needed to deal with the differential in expansion and contraction between the ceramic layers and the metal in order to achieve better adhesion between the ceramic and metal. 
   Better adhesion of the ceramic material to the metal has been achieved by this present invention by providing a plurality of ceramic disks substantially covering the wear surfaces of the valve assembly to provide improved abrasion-resistance and which are of a size that is not significantly affected by the differences in coefficient of expansion and contraction of the ceramic and metal materials. An improved adhesion of the ceramic material to the metal wear surfaces is also accomplished by attaching the ceramic disks within cylindrical recesses extending into the wear surfaces. This provides greater surface contact between the disks and the wear surfaces. 
   It has also been found that the adhesion of the ceramic disks within the recesses has been greatly increased by providing notched portions or annular grooves extending around the circumference of the disks and providing and interlocking effect between the grooves and the adhesive flowing into the grooves and curing therein to form radially inwardly extending ribs when cured. 
   It is, therefore, in accordance with a primary aspect of the present invention an object to provide an improved check valve assembly for an injection molding apparatus wherein the service lifetimes of the various working elements is increased such that many more molded products may be produced before it becomes necessary to replace the working elements of the apparatus. 
   In accordance with another aspect of the invention it is an object to provide an improved injection molding apparatus check valve assembly which may be made from less expensive base metal and/or tool steel than now applied for these type elements while also providing an operational service life which is greatly for extended over what is available with presently made check valve assemblies. 
   An even further object of this invention is to provide a plurality of ceramic abrasion-resistant layer ceramic disks substantially covering the wear surfaces which disks may be adhered to the metal wear surfaces without the use of heat being applied to the metal surfaces which might affect the base metal hardness. 
   Another object of the invention is to provide a plurality of abrasion-resistant ceramic disks having lower frictional heat due to density of the disks. 
   An even further object of the invention is to provide a plurality of abrasion-resistant ceramic disks which may be adhesively attached to any hardness of metal. 
   Another object of the invention is to provide a plurality of abrasion-resistant ceramic disks which may be adhesively attached to stainless steel and corrosion resistant high nickel alloys. 
   SUMMARY OF THE INVENTION 
   This invention is a check valve assembly for an injection molding apparatus having a rotatable and axially translatable feed-screw within a barrel bore and adapted for moving a polymeric material through the valve assembly towards an exit chamber of the apparatus, the check valve assembly characterized by: a valve body member attached to the forward end of the feed-screw and moveable with the feed-screw, said body member having at least one valve seat surface thereon, an axially slidable member mounted on the body member for limited axial movement thereon, said slidable member having; at least one valve seat surface which frictionally engages a corresponding valve seat surface on the body member, and a circumferential surface at its outside diameter which frictionally engages the inner surface of the barrel bore, the improvement comprising a plurality of cylindrical recesses extending into at least part of the valve seat wear surfaces, said recesses being filled with abrasion-resistant ceramic disks securely attached therein, said disks effectively reducing frictional wear between coacting frictionally engaging surfaces and between the surfaces and the plasticized material as it is moved through the check valve assembly. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These an other advantages and features of the invention will hereafter appear for purposes of illustration, but not of limitation, in the accompanying drawings, in which like-reference numerals are used to identify like elements and wherein: 
       FIG. 1  is a side elevational view, in cross-section and with various parts broken away, illustrating a state-of-the-art injection molding apparatus as may benefit from the concepts taught by the present invention; 
       FIG. 2  is a greatly enlarged elevational view, in cross-section, of but a portion of the injection molding apparatus shown in  FIG. 1  illustrating the application of the present invention; 
       FIG. 3  is a greatly enlarged elevational view, in cross-section similar to  FIG. 2  but showing a slightly different modification of the invention; 
       FIG. 4  is a rear end view of a conically shaped tip end of an injection molding apparatus showing a valve seat surface; 
       FIG. 5  is a front end view of a check ring of an injection molding apparatus, showing a valve seat surface; 
       FIG. 6  is an enlarged perspective view of an abrasion resistant ceramic disk having an annular groove extending around its periphery; 
       FIG. 7  is an enlarged perspective view similar to FIG. but having two annular rings extending around the periphery of an abrasion resistant ceramic disk; 
       FIG. 8  is an enlarged fragmentary cross sectional view through a wear surface of the injection molding apparatus shown in  FIG. 2 , having a ceramic disk similar to that shown in  FIG. 6 ; and 
       FIG. 9  is an enlarged fragmentary cross sectional view through a wear surface of the injection molding apparatus shown in  FIG. 2 , having a ceramic disk similar to that shown in  FIG. 7 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   In the drawing,  FIG. 1  illustrates an injection molding apparatus generally indicated by reference numeral  10 . The apparatus  10  conventionally comprises a substantially cylindrical barrel  12  having a specific longitudinal length and it will be recognized that only the exit or output end of the barrel  12  is shown in the drawing. Of course, and as is well-known and understood in this art, an input end (not shown) will include a hopper mechanism for feeding various type of consideration of the present invention. The barrel  12  may be characterized by a bore  14  centered on a longitudinal axis as indicated by the line Ax-Ax in the drawing. The exit end of the barrel  12  is generally indicated by reference numeral  16  and it may comprise an end cap member  18  which is affixed at  20  to the end of the barrel  12  by any of various well-known methods and/or techniques. The end cap  18  is characterized by a through-bore  22 , a partial portion of which is conically shaped as at  22   a  and it connects into an exit bore  24  of a nozzle tip  26 . The nozzle tip  26  is adapted for a mating relationship of the injection molding apparatus  10  to a molding machine (not shown) in the well-known and understood manner of such apparatus. 
   A feed-screw member  30  is mounted co-axially within the bore  14  of the extruder barrel  12  and it is characterized by a helically oriented thread  32  having a land portion  34  exhibiting an outside diameter D 1  which is substantially but not exactly equal to the inside diameter D 2  of the bore  14 . A slight frictional engagement between the two is evident when the feed-screw  30  is rotated within the barrel bore  14 . The feed-screw  30  has a body  36  exhibiting an outside diameter D 3  which is less than the outside diameter D 1  of the thread  32  by a specific amount and it may be appreciated that a rotation of the feed-screw  30  will effect a movement of any material caught between the outside surface of the feed-screw body  36  and the inside surface of the bore  14  toward the exit end  16  of the apparatus  10 . 
   The feed-screw member  30  has an extruder check valve assembly  40  mounted to its forward end and valves of this type may comprise two or more separate but co-operating parts or elements as evidenced in various of the prior art patents. The particular check valve  40  shown in the drawing comprises a valve body  42  characterized by a conically-shaped tip end  44  and a shank end  46  which has a plurality of threads  48  for a portion of its length. The valve body  42  is affixed to the forward end of the feed-screw  30  by way of the shank end  46  being threadably engaged within a threaded bore  38  at the end of the feed-screw  30 . The conically-shaped tip end  44  is shaped to mate with the conically-shaped bore  22   a  such that any material within the forward portion of the barrel bore  14  will be forceably directed into the exit bores  22  and  24  and out of the exit orifice  28  by an axial movement of the feed-screw  30  into the end cap member  18 . It is, of course, well-recognized and understood that the feed-screw  30  is connected to a power source (not shown) which controls its rotational and/or axial motion and the particular power means, therefore, is not important to the scope of the present invention. 
   The shank end  46  of the valve body  42  has a shoulder  50  formed between the smaller diameter threaded portion  48  and a larger diameter valve passage portion  52 , the shoulder  50  providing an axial stop for a valve seat ring  54  carried on the smaller diameter portion  48 . The valve seat ring  54  has a forwardly-facing valve seat bearing surface  56  and it is further characterized by an outside diameter which is substantially equal to the diameter D 3  of the feed-screw body  36 . As clearly evident in the drawing, the valve seat ring  54  is maintained in position between the shoulder  50  and the terminal end of the feed-screw  30  when the valve body  42  is threadably engaged within the bore  38  in the end of the feed-screw. 
   The valve seat ring  54  comprises the rearward valve seat surface  56  of the check valve assembly  40  while a forward valve seat surface  58  is formed on a backside annular surface of the conically-shaped tip end  44 . The forward valve seat  58  has a number of axially oriented flute passages  60  passing therethrough and the purpose of these will become apparent as this description proceeds. 
   The check valve assembly  40  further comprises a check ring member  70  which is mounted about the shank portion  52  of the shank end  46  and it is movable in the axial direction between the rearward valve seat  56  and the forward valve seat  58 . The check ring  70  is further characterized by frustoconical valve seat surfaces  72  and  74 , the valve seat surface  72  being in a position to sealingly engage the rearward valve seat  56  of the valve seat ring  54  while the valve seat surface  74  is in a position to sealingly engage the forward valve seat surface  58  on the valve body  42 . The valve seat surfaces  56 ,  58 ,  72 , and  74  are obviously mating surfaces and these may be disposed at an angle within the range of 0°-30° with respect to a radially oriented plane which is positioned orthogonally on the Ax axis. 
   Further with respect to the check ring member  70 , it has an outside diameter surface  75 , which is substantially but not exactly equal to the inside diameter D 2  of the bore  14 . While a sealing type engagement is effected as between the check ring  70  and the bore wall  14  such that material moving through the bore may not pass therebetween, the check ring is movable in the axial direction so as to be alternately engageable with either of the forward valve seat surface  58  or the rearward valve seat surface  56 . The check ring  70  also has an inside bore diameter which is larger than the outside diameter of the the forward portion  52  of the shank end  46  about which it is mounted. In this configuration, an annular passage indicated at reference numeral  76  is evident and it provides a pass-through for polymeric material when the check valve the check valve assembly  40  is in the “valve-opened” position as shown in the drawing. 
   In the operation of the injection molding apparatus  10 , it will be recognized that a material distribution chamber generally indicated by reference numeral  80  may be establish ed between the tip end  44  of the check valve assembly  40  and the conically-shaped bore  22   a  of the end cap member  18 . When the volume of the distribution chamber  80  is established for a particular molded part, the feeds crew  30  is maintained in its axial position within the barrel bore  14  but it is rotated about the Ax axis. This rotation of the feed-screw  30  effectively moves polymeric material being fed into the barrel  12  longitudinally down the bore  14  towards the exit end  16 . The movement of material effectively also moves the check ring  70  into axial engagement with the forward valve seat surface  58  as shown in the drawing. Polymeric material is thus able to move through the check valve assembly  40  by way of the open annular passage  76  and the axial flute passages  60  and then into the distribution chamber  80 . As the distribution chamber  80  is filled, an injection stroke of the feed-screw  30  causes the check ring  70  to move into axial engagement with the rearward valve seat surface  56  of the valve seat ring  54 . Initiation of this powerful injection stroke of the feedscrew  30  in the axially forward direction forces any material within the chamber  80  out of the exit orifice  28  and into a relatively positioned molding chamber (not shown). 
   From the foregoing description of the injection molding apparatus  10 , it must be appreciated that the relative motions as between the various member elements of the apparatus generates heat which also increases the friction component as between the members. This is further aggravated by heat being generated within the polymeric material as it is processed through the apparatus and by a friction component which exists as between the material itself as it passes over the various member element surfaces. It will, of course, be recognized that the operational service life of the various members will be shortened by the amount of wear of critical surfaces and especially the valve seat surfaces of the check valve assembly  40  which actually govern the operation of the injection molding process. Referring now to  FIG. 2  of the drawings, a greatly enlarged elevational view of a portion of the apparatus  10  of  FIG. 1  is illustrated. In this figure, like-reference numerals are used to designate like elements of  FIG. 1  and the primed reference numerals are used to indicate the improved elements of the apparatus in accordance with the concepts of the present invention. 
   The showing of  FIG. 2  is of the forward end of the feed-screw member  30  which carries the check valve assembly  40  in axial position at it forward end. The check valve assembly  40 ′ shown in  FIG. 2  is an improved design wherein various of the element surfaces which exhibit exceptional wear and which are critical to the operation of the injection molding apparatus are substantially covered with a plurality of substantially abrasion-resistant ceramic disks  59 ′ securely attached within a plurality of cylindrical recesses  61 ′ in at least the flat annular wear surfaces  58 ′ and  74 ′, which disks, dramatically increases the operational service life of the check valve assembly  40 ′. When using the disks  59 ′, the flat annular surfaces  58 ′ and  74 ′ are preferable to the frustoconical surfaces  58  and  74  shown in  FIG. 1 . 
   In  FIGS. 4 and 5 , the disks  59 ′ positioned in the valve seat surfaces  58 ′ and  74 ′ are shown in their relative locations around the valve seats  58 ′ and  74 ′ respectively. 
   To produce the disks  59 ′, ceramic materials taken from the group comprising the ceramic oxides may be fired to the desired hardness and formed into a plurality of disks  59 ′ of a size to cover a substantial portion of the wear surface and adhesively attached to the wear surface such as shown in  FIG. 2  by attaching them in recesses  61 ′. 
   After the disks  59  are attached to the selected wear surfaces of the valve parts, the disks and wear surface can then be machined to the desired final gauge thickness so that the outer surface of the disks are flush with the wear surface it is mounted in. For such ceramic disks, a final gage thickness of between ⅛ and ¼ inches, (3.175 and 6.350 mm) is preferable. 
   One of the preferred ceramic materials which provides an excellent abrasion resistance is a high alumina aluminum oxide. Another ceramic oxide which is also a good choice for abrasion resistance is zirconia and in particular Cerium Oxide Partially Stabilized Tetragonal Zirconia Polycrystal. 
   The ceramic oxides are considered preferable for use on the forward valve seat surface  58 ′ on the back side of the conically shaped tip end  44 . 
   The ceramic disks  59 ′ described previously, are attached to the wear surfaces of the valve by a high temperature adhesive having the required physical properties to withstand the environment in which it is to used within the valve assembly. 
   One of the preferred ceramic materials which provides an excellent abrasion resistance is a high alumina aluminum oxide. Another ceramic oxide which is also a good choice for abrasion resistance is zirconia and in particular Cerium Oxide Partially Stabilized Tetragonal Zirconia Polycrystal. 
   The ceramic oxides are considered preferable for use on the forward valve seat surface  58 ′ on the back side of the conically shaped tip end  44 . 
   With regard to wear surfaces other than  58 ′ and  74 ′, a bonded metallic coating shown in stippled areas is applied to the valve seat ring surface at  56 ′, the check ring valve seat surface  72 ′, and the check ring outside diameter surface  75 ′. 
   The bonded coating preferably comprises a metal and/or metal alloy exhibiting a density of at least gm/cm 3  at 20°. These may be spray-coated on the desired surface by a technique and/or process know in the metallurgical art as “High Velocity Oxygen Fuel Coating”, which is carried out using specific type equipment at over 1927° C. 
   The bonded coating material is preferably applied to a gage thickness of not more that 0.030 inch, (0.762 mm) after which the surface is machine-ground to a gauge thickness within the range of 0.005-0.025 inches, (0.127-0.635 mm). Preferably after the grinding operation, the coating material exhibits a gauge thickness of at least 0.006 inch, (0.152 mm). Metal and/or metal alloys of the type alluded to are preferably a mixture of tungsten carbide, cobalt and other elements selected from the group of iron, carbon, nickel and chromium. 
   In addition to metal and/or metal alloy bonded coatings, it will be recognized that various types of ceramic materials may provide the desired abrasion resistance and these may also applied in a manner similar to the valve seat and other frictionally engaging wear surfaces. 
   This invention, therefore, is not limited to a particular ceramic, metal and/or metal alloy layer but, in the broadest sense covers any high abrasion-resistant material which may be adhesively attached or if carbide coating are used, they are attached to the wear surfaces by spray coating by the High Velocity Oxygen Fuel Coating process. 
   Finally, it will also be recognized that when such abrasion resistant coatings are used, the underlying base metal may comprise a less expensive metal and/or metal alloy than presently being used for these parts. For example, the very expensive tool and alloy steels presently being used for the valve seat ring  54  and the check ring  70  may be replaced with a number 4150 steel which costs ninety-five percent less. Obviously, a great savings in materials may be realized by the application of the present invention. 
     FIG. 3  shows a different embodiment from that shown in  FIG. 2  in which similar parts are shown with a double prime (″) instead of a single prime (′) as used in  FIG. 2 . In  FIG. 3 , the rear end of the conical shaped tip end  44 ′″ is divided into two parts with a bead seat ring  45  positioned against the rear end of the tip end  44 ″. A valve seat ring  54 ″ has a forward tubular extension  55  which bears against a rear annular surface  45   a  on the ring  45  and holds it in position. All the remainder of the wear surfaces  56 ″,  58 ″,  72 ″,  74 ″ and  75 ″ are similar to those similar numbers described in  FIG. 2 . Except for the addition of ring  45  and tubular extension  55 , all the rest of the parts of the assembly shown in  FIG. 3  are the same as in  FIG. 2  and the disk material of ceramic oxide or coating carbide material can be used. It should also be noted that the wear surfaces  58 ″ and  74 ″ are flat annular surfaces similar to the surfaces  58 ′ and  74 ′ in  FIG. 2 . 
     FIGS. 6-9  show a modified version of the abrasion resistant ceramic discs  59 ′ and  59 ″ shown in  FIGS. 2 and 3 .  FIG. 6  shows a disk  59   a  with a single annular groove  78  extending around the periphery of the disk and  FIG. 7  shows a disk  59   b  with a pair of annular grooves  80  extending around the periphery of the disk. 
     FIG. 8  shows the disk  59   a  adhesively attached in a recess  61 ′ of a valve seat  58 ′. 
   Likewise  FIG. 9  shows the disk  59   b  adhesively attached in a recess  61 ′ of a valve seat  58 ′. A high temperature adhesive is used to fasten the disks  59   a  and  59   b  in the recesses  61 . The purpose of the annular grooves  78  and  80  is to provide a space into which the adhesive can flow and provide and interlocking relationship between the adhesive and the periphery of the disk when the adhesive cures and thereby fasten the disks  59   a  or  59   b  more securely in the recesses  61 . 
   It will be recognized that various shapes of notches or grooves can be placed in the periphery of the ceramic disks to improve the retention of the disk by the adhesive. 
   While certain representative embodiments and details have been shown for the purpose of illustrating the invention, it will be apparent to those skilled in this art that various changes and/or modifications may be made therein without departing from the spirit or scope of the invention.