Hot Runner Technology Examples of Hot Runners in use

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Illustrations simplified, schematically drawn and not to scale.

For a specific application, please consult Synventive.

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Examples of Hot Runners in use

Hot Runner Technology

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1 g

2 g

5 g

5 g7 g

8,6 g

15 g

21 g2 g

20 g13 g10 g7 g

150 g

150 g

220 g

1400 g

2500 g

2500 g

5000 g

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PP

PE

PA 6 V0

PS metallicPS cust. col.

POM

PC / ABS

POMTPE

PPPPPPPP

PP GF20

ASA

PP

PP / EPDM

PPO GF10

PP LGF30

PC

For a specific application, please consult Synventive.2008-07-30 - All rights reserved. Errors and omissions excepted.

Housing cover

Bottle cap

Modular terminal

Aircraft cutlery

Car window mechanism

Mobile telephone

Conveyor belt

Needle dispenser

Car air condition

Car bumper

Car interior

Car body

Car interior

Car body

Car body

Cap insert

Cap

Terminal body

Fork (prongs and handle)

Guide wheel

Lower casing

Chain link (chain body & cleats)

Cartridge (housing & 3 inner rings)

Fan wheel

Bumper strip

C-pillar cover

Wheel arch liner

Instrument panel support

Front end module

Car window

What is the purpose of this compilation of examples?

What is shown here in detail?

Important copyright note

The collection of practical application examples shown here is intended to help everyone who uses the hot runner technology, wishes to use the technology or simply wants to find out about the technology in the following way:

èBroadest possible insight into hot runner technologyèSupplementary aid to selecting the appropriate hot runner componentsèOverview of different solutions in the field of gating technology

All the examples are based on applications that were implemented using Synven-tive hot runner technology. The choice was made under the following aspects:

èDifferent examples in order to include as many fields of application as possibleèLimitation to the most important key dataèGuaranteeing of data security by the use of schematic illustrationsèIllustration of original parts only after approval by the manufacturer

All examples and their data may only be used for their own information by persons to whom this compilation of examples was supplied by authorised representatives of Synventive Molding Solutions. Passing on information, in whole or in part, requires the written approval of Synventive.

64-cavity mould

8-cavity mould

2-cavity mould, flame retardant

16+16-cavity turntable mould2-component moulding

4+4-cavity stack mould

2-cavity mould

4+4-cavity turntable mould2-component moulding

2+2+2+2-cavity family mould

2-cavity mould

Single-cavity mould, cascade moulding

Car interior, textile moulding

1+1-cavity family mould

Single-cavity mould, long glass fiber material

Single-cavity mould

1+1-cavityRotary stack mould

Examples of Hot Runners in useHot Runner Technology

Weight Material Moulded Part(s)Page Application Mould Type / Remarks

Contents

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TW

04C W01T

04 VC + C

1 g PP

MK

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1920

05-1

0-14

1 2

Cap insertHousing cover1 gPPMulti-cavity mould64

Customer requirements

In this particular application, it was a question of manufacturing PP caps in a 64-cavity mould with fast delivery of the complete, pre-wired and adjusted system, including mould plates, connection box and connector-ready, pre-configured temperature controller.

This application was implemented using an externally heated, 64-cavity hot runner system with face fit between nozzles and manifold. The manifold system consisted of 2 block manifolds with 32 nozzles each, fed by an H-manifold. All runners are naturally balanced. Gating with the hot runner was direct, in the centre of the moulded part. To suit this system with a large number of cavities, a mobile temperature controller was supplied, ready to plug in.

èresources through the "hot half concept" as initial stage of the finished mould half

èManufacture without sprue waste and post-processing

èProduction with high number of cavitiesèGood gating quality regarding gate mark

and appearanceèEqual supply and filling of all cavities with

meltèGood moulded part quality from all

cavities

Saving of time and manufacturing

Solution

Benefits

Schematic product overview

1. Manifold nozzle, face fitNozzle class 04 C

2. ManifoldSeries VC

Cap insert for housing cover

Key data

Moulded partApplicationPart weightMaterialMould typeNo. of cavities

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CB WT M

TW07 VC + C

2 g PE

MK

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2005

-04-

13

1 2

Cap for foodstuff bottle

CapFoodstuff bottle2 gPEMulti-cavity mould8

Customer's requirements

This application involved the production of caps of PE for foodstuff bottles in an 8-cavity mould.

In the implementation of this application, an externally heated 8-port hot runner system with face fit manifold nozzles was employed. The manifold was in the standard manifold form (H) and its runners were naturally balanced. The cavity was directly gated with the hot runner to the moulding surface via open nozzles with torpedo.

èProduction without sprue waste and without reworking

èGood gating quality with respect to separation and appearance

èUniform supply and filling of all cavities with melt

èGood moulding quality from all the cavities

1. Manifold nozzle with sliding mounting Series CB…M, Type WT, Class 07 C2. Manifold Series VC

Solution

Benefits


Key data


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CB FT M

07 VC + C

5 g PA 6 V0

1 2

TF

MK

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16

2003

-06-

03

Terminal body for modular terminal

1. Manifold nozzle, face fit Series CB...M, Type FT, Class 07 C2. Manifold Series VC


Terminal bodyModular terminal5 gPA 6 V0Multi-cavity mould2


This application involved the production of modular terminals of PA 6 with V0 properties in a 2-cavity mould.

In the implementation of this application, an externally heated 2-port hot runner system with face fit manifold nozzles was employed. The manifold was of standard form (I) and its runners were naturally balanced. The cavity was directly gated with the hot runner to the moulding surface via open nozzles with torpedo, whereby the gate was recessed in a dimple.





Solution

Benefits

Key data


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N CB W M

VW07 VC + F

System 1 àPS metallic System 2 àPS custom color

5 g PS metallic + 7g PS custom color

1 2 3

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32

2004

-08-

13

Fork for aircraft cutlery

1. Manifold nozzle, face fit Series N CB...M, Type WV, Class 07 C2. Manifold Series VF3. Actuator, pneumatic, in mould plates Series LCP 4008 02


Fork: Prongs and handleAircraft cutlery5 g + 7 gPS: metallic & cust. colourTurntable mould16 + 16


This application involved the production of forks of PS for aircraft cutlery using the 2-component process with a 16+16-cavity turntable mould. The plastic cutlery is to replace the metal cutlery used to date.

In the implementation of this application, two identical externally heated 16-gate hot runner systems with nozzles sliding on the manifold were employed. The runner systems each consisted of two T-shaped runners linked by an I-shaped runner. The cavity was directly gated with the hot runner to the moulding surface via valve gate nozzles with 4 nozzles being actuated by one actuator. The system was supplied as hot half, i.e. including mould plates, ready installed and adjusted as well as wired ready for plugging in and with the necessary hose connections.

èSavings in time and costs thanks to the “hot half concept” as the preliminary stage to the finished mould side


èProduction with a large number of cavitiesèGood gating qualityèUniform supply and filling of all cavities

with meltèGood moulding quality from all the cavities

Solution

Benefits

Key data

Moulded partsApplicationPart weightMaterialMould typeNo. of cavities

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M CB WT M

07 VC + C TW

8.6 g POM

1 2

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0320

03-1

0-06

Guide wheel for car window mechanism

Guide wheelCar window mechanism8,6 gPOM: Hostaform C9021Stack mould8


This application involved the production of guide rollers of POM for the car window mechanism with the largest possible number of cavities on an existing, relatively small injection moulding machine. The cavities were to be gated directly with the hot runner and at several points around the perimeter of the moulding in order to ensure good concentricity.

In the implementation of this application, an externally heated 8-port hot runner system with mutli-tip face fit manifold nozzles was employed. The runner was designed in an H shape and had a long gating neck due the stack design of the mould. The nozzles were positioned on both sides of the runner. The cavity was directly gated via open multi-tip nozzles with torpedo at 3 points on the side surface of each moulding.

èProduction with a relatively large number of cavities on the existing machine

èGood concentricity of the mouldingsèProduction without sprue waste and

without reworkingèGood gating quality with respect to

separation and appearanceèUniform supply and filling of the mould

cavities

1. Manifold nozzle, face fit Series M CB...M, Type WT, Class 07 C2. Manifold Series VC

Solution

Benefits


Key data


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15 g PC/ABS

CB WT M

TW07 VC + C

MK

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0120

05-0

3-31

1 2

1. Manifold nozzle with sliding mounting Series CB...M, Type WT, Class 07 C2. Manifold Series VC


Lower casingMobile telephone15 gPC/ABSMulti-cavity mould2


This application involved the production of lower casings for mobile telephones of PC/ABS. The cavities were to be directly gated via the hot runner to the moulding surface in a spherical dimple.

In the implementation of this application, an externally heated 2-port hot runner system with face fit manifold nozzles was employed. The cavity was directly gated with the hot runner to the moulding surface via open nozzles with torpedo, whereby the gate was recessed in a spherical dimple.





Solution

Benefits

Lower casing for mobile telephone

Key data


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07 V12 S C + C

21 g POM + 2 g TPE

N VK X

GA KN E N CB X M

System 1 àPOM System 2 àTPE

1 2 3 4

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27

2004

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28

1. Single nozzle Series GA...E, Type KN, Class 12 S2. Manifold nozzle, face fit Series N CB...M, Type XV, Class 07 C3. Manifold Series VC4. Actuator, pneumatic, in mould plate Series LCP 4008 02


èSavings in time and costs thanks to the “hot half concept” as the preliminary stage to the finished mould side


èProduction with a large number of mould cavities




Benefits

Chain linkConveyor belt21 g POM + 2 g TPEPOM + TPETurntable mould4 + 4


This application involved the production of chain links of POM and TPE for conveyor belts in a 4 + 4-cavity turntable mould using the 2-component process.

Solution

In the implementation of this application, a single nozzle was used for the POM component and a 4-gate runner system with valve gate nozzles with face fit to the manifold for the TPE component. The cavities were directly gated on the one hand via a cold sub-runner (POM) and on the other with valve gate nozzles directly to the moulding (TPE). The system was supplied as a hot half, i.e. including mould plates, ready installed and adjusted as well as wired ready for plugging in and with the necessary hose connections.

Chain link for conveyor belt

Key data


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TW

03 C01 W01T

04 C01 W01T

CB XT M

TX 070403 VCCC +++ C

20 g + 13 g + 10 g + 7 g PP

1 2

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3720

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6-26

1. Manifold nozzles, face fit Series 03 C01, Type WT, Class 03 C Series 04 C01, Type WT, Class 04 C Series CB...M, Type XT, Class 07 C2. Manifold Series VC


Housing + 3 inner ringsNeedle dispenser20 g, 13 g, 10 g, 7gPPFamily mould2 + 2 + 2 + 2


This application involved the production of a four-piece module of PP, a housing and three inner rings. They formed the heart of a cartridge housing. The components were to be produced in a family mould with which two complete modules could be produced in one shot.

In the implementation of this application, a rheologically balanced, externally heated 7-port hot runner system with face fit manifold nozzles was employed. Manifold form and nozzle lengths were specially adapted to the part contour and the required injection points. The cavities were gated via cold sub-runners that were fed by open nozzles with torpedo. The outstanding feature of this system lies in the combination of nozzles of three different sizes on one manifold, whereby the largest of the nozzles feeds two cavities.

èTwo complete modules in one shot with one mould on one machine

èAssembly of the modules directly at the machine without long transport routes or complex logistics

èGood, uniform moulding quality from all the cavities

èHigh productivity

Solution

Benefits

Components for needle dispenser

Key data

Moulded partsApplicationPart weightMaterialMould typeNo. of cavities

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12 E01 W01V

VW

150 g PP GF20

+®Dynamic Feed

12 VE + F

MK

-PR

M.S

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-

A.C

S00

2920

04-1

2-08

t

p

START

1 2 4 5

6

7

3

1. Manifold nozzle, face fit Series N GA...M, Type WV, Class 12 C2. Manifold Series VE3. Melt valve block DFTB with pressure

transducer4. Actuator, hydraulic, bolted Series HYC 4520M 015. Servo valves (and pressure generator)6. PID controller DFC7. Start signal from the injection moulding

Fan wheel for car air condition

Fan wheelCar air condition150 gPP GF20Multi-cavity mould2


This application involved the production of fan wheels for car air conditioning systems with a 2-cavity mould. Until now the fan wheels had been produced with a single-cavity mould to ensure the necessary precision. The demand on the production with a multi-cavity nozzle was that at least the same precision in dimensions and concentricity be achieved.

In the implementation of this application, an externally heated 2-port hot runner system with face fit manifold and melt pressure control was employed. The runner was designed in the standard form (I). The cavity was gated via cold sub-runners that were fed by valve gate nozzles. A pressure-controlled melt valve was installed upline of each nozzle with which the flow cross-section in the runner could be varied dynamically and infinitely online and in real time or could be held constant. This permitted not only gentle opening and closing but also the generation of individual pressure profiles and hence individual filling conditions during the filling and holding pressure phases for each individual nozzle.

Solution

èOptimised and variable filling conditions for each individual cavity

èTwice the productivity in the same timeèIncreased production qualityèConstant quality shot for shot

Benefits


Key data


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START

T 20 - CV10

186 g + 92 g PP

+®Dynamic Feed

T V20 + H

1 2 4 5

6

7

3

MK

-PR

M.S

IS.

-

A.C

S00

2420

04-1

2-08

10CV

R L

1. Manifold nozzle, face fit Series N GA...M, Type WV, Class 12 C2. Manifold Series VE3. Melt valve block DFTB with pressure

transducer4. Actuator, hydraulic, bolted Series HYC 4520M 015. Servo valves (and pressure generator)6. PID controller DFC7. Start signal from the injection moulding

Shell, inner supportCar interior186 g, 92 gPPFamily mould1+1+1+1


In the implementation of this application, an externally heated 2-port hot runner system with face fit manifold and melt pressure control was employed. The runner was designed in the standard form (I). The cavity was gated via cold sub-runners that were fed by valve gate nozzles. A pressure-controlled melt valve was installed upline of each nozzle with which the flow cross-section in the runner could be varied dynamically and infinitely online and in real time or could be held constant. This permitted not only gentle opening and closing but also the generation of individual pressure profiles and hence individual filling conditions during the filling and holding pressure phases for each individual nozzle.

Solution

èOptimised and variable filling conditions for each individual cavity

èIncreased production qualityèConstant quality shot for shot

Benefits


Key data


B-pillar cover for car interior

This application involved the production of covers for B-pillars with a family mould. The cover consisted of the outer shell and the inner support. Both parts were to be mounted together after being moulded. Due to qualitiy and stability reasons both parts had to be made from the same material and produced under the same conditions.

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16 E01 L01V

VL

150 g ASA

+®Dynamic Feed

16 VE + F

1 2 4 5

6

7

3

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26

2004

-04-

08 1. Manifold nozzle, screw fit Series 16 E01, Type LV, Class 16 E2. Manifold Series VF3. Melt valve block DFTB with pressure transducer4. Actuator, hydraulic, bolted Series HYC 4520M 015. Servo valves (and pressure generator)6. PID controller DFC7. Start signal from the injection moulding



This application involved the production of decorative strips for the front bumper of a car. The mould was to be filled in a cascade, avoiding flow lines and marks on the mouldings.

In the implementation of this application, an externally heated 5-port hot runner system with valve gate nozzles screwed into the runner and melt pressure control was employed. Manifold form and nozzle lengths were specially adapted to the part contour and the required injection points. The cavity was gated via cold sub-runners that were fed by valve gate nozzles. A pressure-controlled melt valve was installed upline of each nozzle with which the flow cross-section in the runner could be varied dynamically and infinitely online and in real time or could be held constant. This permitted not only gentle opening and closing but also the generation of individual pressure profiles and hence individual filling conditions during the filling and holding pressure phases for each individual nozzle.

èPressure-controlled cascade filling from the middle of the moulding

èGentle and infinitely variable opening of individual nozzles

èRoughly identical melt front velocity over the whole moulding length

èHigh surface quality, no flow linesèHigh dimensional accuracy and form

stability

Solution

Benefits

Bumper stripCar bumper150 gASASingle-cavity mould1

Decorative strip for car bumper

Key data


Photo: Ford

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16 E02 L01V

VL16 VE + E

220 g PP + PES

1 2 3

MK

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M.S

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3520

06-0

6-26


This application involved the production of textile-lined covers for car C-pillars using the textile moulding process. The main body of the cover was to be of PP, the textile surface of PES. The mould filling had to be correspondingly gentle and uniform, in a cascade without flow lines. The cover for the right-hand side was to be produced in a family mould together with the cover for the left-hand side.

In the implementation of this application, an externally heated 10-port runner system with long, narrow screw fit valve gate nozzles was employed. The form of the manifold was adapted specially to the contour of the part and the respective required injection points. The cavity was directly gated with sprue to the rear of the moulding via valve gate nozzles.

èGentle back-filling of the textileèAdequate space in the mould thanks to

the narrow design of the nozzlesèDeep insertion into the mould and

connection at the optimum pointsèGood, uniform moulding quality from all

the cavitiesèMoulding production and surface

lamination in a single step

Solution

Benefits

C-pillar coverCar interior220 gPP + PESFamily mould1+1

C-pillar cover for car interior

1. Manfiold nozzle, screw fit Series 16 E02, Type LV, Class 16 E2. Manifold Series VE3. Actuator, hydraulic, bolted Series HYC 4018M 01


Key data


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22 VE + F

1400 g PP LGF10

MK

-PR

M.S

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A.C

S00

3520

06-0

6-26

22 E01 V01V

VV

1 2 3


This application involved the production of textile-lined covers for car C-pillars using the textile moulding process. The main body of the cover was to be of PP, the textile surface of PES. The mould filling had to be correspondingly gentle and uniform, in a cascade without flow lines. The cover for the right-hand side was to be produced in a family mould together with the cover for the left-hand side.

In the implementation of this application, an externally heated 10-port runner system with long, narrow screw fit valve gate nozzles was employed. The form of the manifold was adapted specially to the contour of the part and the respective required injection points. The cavity was directly gated with sprue to the rear of the moulding via valve gate nozzles.

èGentle back-filling of the textileèAdequate space in the mould thanks to

the narrow design of the nozzlesèDeep insertion into the mould and

connection at the optimum pointsèGood, uniform moulding quality from all

the cavitiesèMoulding production and surface

lamination in a single step

Solution

Benefits

C-pillar coverCar interior220 gPP + PESFamily mould1+1

C-pillar cover for car interior

1. Manfiold nozzle, screw fit Series 16 E02, Type LV, Class 16 E2. Manifold Series VE3. Actuator, hydraulic, bolted Series HYC 4018M 01


Key data


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16 E02 V01V

VV

1400 g PP/EPDM

+®Dynamic Feed

16 VE + F

MK

-PR

M.S

IS.

-

A.C

S00

0520

02-1

0-09

t

p

START

1 2 4 5

6

7

3

Wheel arch liner for car body

Wheel arch linerCar body1400 gPP/EPDMFamily mould1+1


This application involved the production of wheel arch liners for car bodies. The wheel arch liner for the right-hand side was to be produced in a family mould together with the wheel housing liner for the left-hand side.

In the implementation of this application, an externally heated 6-port hot runner system with screw fit valve gate manifold nozzles and melt pressure control was employed. Manifold form and nozzle lengths were specially adapted to the part contour and the required injection points. The cavity was directly gated with hot runner to the surface of the moulding via valve gate nozzles or with sprue via valve gate nozzles. A pressure-controlled melt valve was installed upline of each nozzle with which the flow cross-section in the runner could be varied dynamically and infinitely online and in real time or could be held constant. This permitted not only gentle opening and closing but also the generation of individual pressure profiles and hence individual filling conditions during the filling and holding pressure phases for each individual nozzle.

èDifferentiated, optimum filling of the different cavity areas

èAvoidance of overfilling in part-areas of the cavity

èReduction in cycle time and reworkingèIncreased productivity during series

production of more than 30%èGood, uniform moulding quality from all the

cavities

1. Manifold nozzle, screw fit Series 16 E02, Type V V, Class 16 E2. Manifold Series VF3. Melt valve block DFTB with pressure transducer4. Actuator, hydraulic, bolted Series HYC 4520M 015. Servo valves (and pressure generator)6. PID controller DFC7. Start signal from the injection moulding

Solution

Benefits


Key data


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22 E01 V01V

2500 g PP LGF30

VV22 VE + F

MK

-PR

M.S

IS.

-

A.C

S00

28

2004

-08-

13

1 2 3

Front end module for car body

Front end moduleCar body2500 gPP LGF30Single-cavity mould1


This application involved the production of plastic front end modulse of long glass fibre-reinforced PP for use in car bodies. The cavity was to be filled sequentially.

In the implementation of this application, an externally heated 11-port runner system with long, narrow screw fit valve gate manifold nozzles was employed. Manifold form and nozzle lengths were specially adapted to the part contour and the required injection points. The cavity was gated both directly with hot runner to the moulding surface and via cold sub-runners. Both were equipped with valve gate nozzles. The hot runner system was correspondingly optimised and equipped for the processing of long glass fibre-reinforced material.

èGentle processing and minimised glass fibre shortening thanks to optimised and runner and correspond equipment of the hot runner system

èOptimisation of the mould cavity filling by temporally offset opening and closing of the needles

èOptimum positioning of the gates for filling thanks to runner form and nozzle lengths adapted to the moulding contour

èProduction with minimised sprue waste

1. Manifold nozzle, screw fit Series 22 E02, Type V V, Class 22 E2. Manifold Series VF3. Actuator, hydraulic, bolted Series HYC 4018M 01

Solution

Benefits


Key data


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2500 g PPO GF10

N EZ L G VHYZ

HYC 4018M 01

a)

16 E02 L01V

b)

VL16 VE + E

MK

-PR

M.S

IS.

-

A.C

S00

30

2001

-10-

20

1 2 3

1. Manifold nozzle, screw fit Series 16 E02, Type LV, Class 16 E2. Manifold Series VF3. Actuator, hydraulic, bolted Series HYC 4018M 01


Dash boardCar interior2500 gPPO GF10Single-cavity mould1


This application involved the production of dash boards of PPO with 10% glass fibre content for the car interior using the cascade process.

In the implementation of this application, an externally heated 10-port runner system with screw fit nozzles was employed. Manifold form and nozzle lengths were specially adapted to the part contour and the required injection points. The cavity was gated directly with hot runner to the surface of the moulding via needle valve nozzles.

a) Original delivery condition, previous series components

b) Current situation, current series components


èDirect gating of the demanded injection points


èPossibility of influencing the mould cavity filling thanks to the valve gate nozzles operating in a cascade

Solution

Benefits

Dash board for car interior

Key data


16 / 16

C P

T A



All

right

s re

serv

ed. E

rror

s an

d om

issi

ons

exce

pted

.G

B

22 2216V VE EE+ ++F F

22 E01 K01N 22 E02 V01V

16 E01 V01V

NK VV

3 4 51 2

5000 g PC

System 1 àPC transp.

System 2 àPC black

MK

-PR

M.S

IS.

-

A.C

S00

3420

06-0

6-26

1. Manifold nozzle, screw fit Series 22 E02, Type V V, Class 22 E2. Manifold Series VF4. Manifold nozzle, screw fit Series 22 E01, Type KN, Class 22 E Series 16 E01, Type V V, Class 16 E5. Actuator, hydraulic, bolted Series HYC 4018M 01


Car window for car body

Car windowCar body5000 gPCRotary stack mould1+1


This application involved the production of windows of PC for cars. The transparent base element of the window was to be produced using the injection-compression moulding process and then surrounded with a dark edge in the 2-component process. The mould for this process was designed as a turning platen mould.

In the implementation of this application, an externally heated 1-port runner system with a screw fit manifold nozzle was employed for the production of the base element. The cavity was gated made via a film gate with sprue that was fed by an open nozzle. For the dark edge of the window, an externally heated 11-port runner system with long, narrow screw fit valve gate manifold nozzles was employed. Manifold form and nozzle lengths were specially adapted to the part contour and the required injection points. The cavity was gated directly with hot runner to the surface of the moulding via valve gate nozzles.

èGentle and clean melt transportèDirect connection of the demanded

injection pointsèGood gating quality with respect to

separation and/or appearance

Solution

Benefits

Key data


Photo: Webasto

Hot Runner Technology Examples of Hot Runners in use

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