New offerings in the running New hot runner systems were introduced last year, at the NPE show in Chicago, US, and the Fakuma show in Friedrichshafen, Germany. For medical/packaging applications German company Heitec Hot Runner Systems extended its Star-Line nozzles with a linear multi-tip nozzle, with the tip inserts installed from the parting line of the mould. It is particularly suitable for small cavity spacing and long, thinwall parts like pipettes or syringe barrels. With a parallel arrangement of the nozzles, parts can be gated directly from two sides, preventing the deflection of thin cores from the injection pressure.
OEM manifolds. The manifold system is available in sizes ranging from 2 to 96 units.
Ewikon’s HPS III-MH d i re c t s i d e - g a t i n g nozzle has a new gating geometry with lateral melt feed, allowing for direct vertical gating in confined spaces with heated tips or valve gates. The heated tips at 90 degrees are now available with 60, 45 and 30 degrees, allowing the position of the gating point to be closer to the core of the cavity when moulding slim, thinwall tubular parts. Thus, core deflection by the melt pressure, which leads to uneven wall thickness, can be reduced or completely eliminated. US-based Incoe introduced Quick-Flo (QF) hot runners designed for processing commodity resins used in high cavity moulds. The systems add on to the Direct-Flo (DF) Gold hot runners that are used for technical part moulding, with up to 1,000 g shot weights per nozzle. The QF nozzles are available in three sizes with flow channel diameters of 3, 5 and 8 mm, shot sizes from 3-375 g and valve gates with thermal tips. QF systems that use Opti-Flo manifolds, with the company’s partner Beaumont Technologies’s MelfFlipper technology, are said to improve cycle times and processing capability. Incoe also introduced the Axial Protected (AXP) feature for the DF Gold nozzles, with multiple heating zones. This eliminates the time and expense of adding a separate groove over the entire length of the nozzle bore in order to accommodate heater cables. For the PET packaging industry, American Electra Form Industries (EFI), a division of Wentworth Technologies, has a new version of its 2.1 that is configured to be compatible with existing OEM tooling. EFI, which has been supplying hot runners for 30 years, says it offers the new version on all its new moulds and also as a low cost alternative to ageing
Electro Form’s hot runner plate assembly
Ewikon’s nozzle in eightdrop valve gate version with actuator plate
Offering flexibility Husky Injection Molding Systems expanded its Pronto line, which has been around for ten years, with larger nozzle sizes (Ultra 350, 500 and 750) including hot tips and valve gates; more plate sizes and pitch spacing as well as over 100 different manifolds. Italian Thermoplay introduced patented nozzles including the small tip DL-8B. It is used for edge gate injection and when it is required to keep the heated part of the nozzle from the surface of the moulding part, to avoid spots and defects. While not suitable for injecting abrasive materials, it can be used for internal moulding of caps, small parts and extended containers. Another nozzle, FL-1B, with an exended tip and a maximum inclination of 45 degrees is used when the injection point is located in critical positions. Thermoplay’s extended nozzle for tilted side injection
For engineering resins DME upgraded its Stellar 4000 micromoulding line with the 5000 series that comes in a standard format for commodity materials. It features a solid titanium point gate retainer for improved heat isolation and a shielded mini-coil heater that allows for faster heat transfer. For harder-to-process materials like PET, PBT and PA, it has a high performance series featuring an embedded brass heater for improved heat transfer and a through-hole tip sub-assembly that offers wear resistance. 1
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Hot Runners South Korean supplier, Yudo, meanwhile, launched the IO series of hot-tip nozzles with a diamond-like coating for wear resistance. Yudo has also replaced its Bala line of open-tip and valve-gate nozzles with its new WINA system, which is said to reduce heating up to 40%. Swiss company Herzog launched Micro-bolt and BHP-shut-off nozzles to prevent melt drooling and stringing when processing low viscosity materials on small tonnage machines. The melt flow channel is designed for minimal material shear while the shut-off function is done by a bolt mechanism. The injection pressure opens the nozzle and the totally encapsulated springs close it. The heavily loaded parts are coated with a special treatment. Herzog’s poweractuated bolt nozzle with a single, large melt channel is a major advantage when processing shear sensitive materials because no material degradation will occur due to shear stress being eliminated inside the nozzle. Another advantage of the BHP nozzle is that different phases in the injection process can be conducted simultaneously, allowing for reduced cycle times. White goods and automotive parts Directed at large part manufacture, Mold-Masters's Fusion G2 system is a newer version of its Fusion series launched a couple of years ago. Boasting a 30% lower price tag, the modular drop-in system comes pre-wired and assembled and has a single point connection for easy installation, simpler maintenance and faster start-ups. The three standard configurations cater to shot sizes from 15-3,500 g per nozzle and nozzle lengths from 90-1,000 mm. Other features are that the screw-in nozzles are threaded directly to the manifold; multiple heater zones per nozzle for optimised thermal profile and a leakproof design. Thermoplay also has a pre-wired system that uses sequential valve gating, with the nozzles and shut-offs fixed to the manifold. A system of joints, which distributes the expansions inside the manifold, allows the use of nozzles without any minimum length. The shut-off valves are provided with a safety switch and a blowing system to avoid overheating on the gaskets. Other features are the reduced thickness of the nozzle plate, improving the melt capacity, and no heating is required during assembly. Temperature controllers Mold-Masters launched the TempMaster K-Series, which was made possible due to its acquisition of PMS Systems. The modular controllers are dubbed as “compact and economical”, especially for hot runners with a high number of temperature zones (up to 240). Benefits include a proven electronic design as a result of the installed base having been around for ten years and easy access for servicing. The unit has a full-colour 10.4 in. touchscreen control, which comes with the latest software improvements. Husky expanded its range of Altanium controllers with the introduction of Neo. While it previously covered one to 12 zones, it is now available for two to 24 zones. Other improvements are an enhanced user interface with upgrades to network connectivity and diagnostics and the ability to store 24 mould set-ups. Thermoplay’s new temperature controller TH-M6 comes with six and 12 zones. It is capable of synchronous heating of all the zones despite differing thermal inertia. An autoslave Mold-Masters’s feature links zones with similar thermal modular temperature behaviour, if there is a thermocouple failure. ◆ controller 2 I n j e c t i o n M o u l d i n g A s ia • F E B R U A R Y 2 0 1 0
IMA features issue February 2010