SR16 Series. Features: All Dimensions in mm SR16-1

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1 Features SR16 Hot Runner Nozzles are for medium part applications and are available with band heaters. In most cases one heater is required for operation. An installed spare may be installed if space allows. They are available in lengths from 75 to 375 ( J dimension). Replaceable Heaters Thermocouple Ø8-16 Suitable for all materials and available with eight Synventive Controlled Vestige (CV) tip options including valve gates for zero gate vestige applications. Heat Pipes Threaded Tips J Features: 16mm maximum flow channel maximum mold depth ("J" dimension) Replaceable long life heater and thermocouple 500W or 600W/40V heaters 8 controlled vestige tip styles Replaceable threaded tips Internal heat pipes for For all plastics including 4 tip dia temperature uniformity those with fillers All imensions in mm SR16-1

2 Heater Heater In most cases one heater is required for operation. If mold thickness allows a spare band heater and thermocouple will be installed. Ø Ø5 H6 6 J Minimum = 75 J Maximum = (J 75 to 149.9) 134 (J 150 to 375) Ø68 J 10 Ø46 SR16-

3 Overview Thermal Gate Nozzle CV10 - Filled and unfilled materials - Open flow channel/higher flow to 5. orifice diameter - Patented seal - Easier mold geometry imensional data on Pages SR16-10, 11 & 1 CV11 - Filled and unfilled materials - Cone point delivers more heat to gate to 3.5 orifice diameter - Patented seal - Reduced vestige - Easier mold geometry imensional data on Pages SR16-13, 14 & 15 CV0 - Filled and unfilled materials - Open flow channel/higher flow to 5. orifice diameter - Patented seal - No witness mark - Easier color change imensional data on Pages SR16-16, 17 & 18 CV1 - Filled and unfilled materials - Cone point delivers more heat to the gate to 3.5 orifice diameter - Patented seal - Reduced vestige - No witness mark imensional data on Pages SR16-19, 0 & 1 See page T16-5 to select a tip that suits your application SR16-3

4 Overview Valve Gate Nozzle VG1 - Filled and unfilled materials - 0 vestige - Tapered shut off orifice diameter - Patented seal - Easier mold geometry imensional data on Pages SR16- & 3 VG1S - Filled and unfilled materials - 0 vestige - iametric shut off - Materials having glass fibers orifice diameter - Patented seal - Easier mold geometry imensional data on Pages SR16-4 & 5 VG3 - Filled and unfilled materials - 0 vestige - Tapered shut off orifice diameter - Patented seal - No witness mark imensional data on Pages SR16-6 & 7 VG3S - Filled and unfilled materials - 0 vestige - iametric shut off - Materials having glass fibers orifice diameter - Patented seal - No witness mark imensional data on Pages SR16-8 & 9 See page T16-6 to select a tip that suits your application SR16-4

5 Material Semi-crystalline SR16 Series Material Compatibility Amorphous Tip Style Additives PE PP PEEK PPS PET PBT PPO/PA PA PPA POM PMMA ABS ASA SAN PS PC/ABS PC PES PSU PEI PPO TPE CV10 A B C CV11 A B C CV0 A B C CV1 A B C The above table defines which tip styles are best suited for a given material. Note: The selection table is meant to be a guide for the initial selection of the tip style. It is based on the more common grades of material. Synventive will verify the correct tip selection as part of the quote/order process. Additive Index A - None B - Fillers C - Glass Fiber - Flame retardants + Very suitable 0 Suitable - Not suitable SR16-5

6 Material Semi-crystalline SR16 Series Material Compatibility Amorphous Tip Style Additives PE PP PEEK PPS PET PBT PPO/PA PA PPA POM PMMA ABS ASA SAN PS PC/ABS PC PES PSU PEI PPO TPE VG1 A B C VG1S A B C VG3 A B C VG3S A B C The above table defines which tip styles are best suited for a given material. Note: The selection table is meant to be a guide for the initial selection of the tip style. It is based on the more common grades of material. Synventive will verify the correct tip selection as part of the quote/order process. Additive Index A - None B - Fillers C - Glass Fiber - Flame retardants + Very suitable 0 Suitable - Not suitable SR16-6

7 Flow Rate Maximum flow rate of hot runner nozzles varies depending on the melt index of the material being processed. Material CV10/CV0 Tip Style CV11(NS)/CV1(N- S) VG1(S)/VG3(S) The flow rate of any hot runner nozzle is controlled by three factors: 1) Flow bore size ) Melt temperature, viscosity vs shear rate relationship. 3) The cavity wall thickness, flow length from the gate, mold temperature and required fill rate. The last two factors can combine to change the maximum shot capacity by a factor of 5 or more. Synventive uses computerized flow analysis to assure the correct nozzle is chosen. ABS PC PPO PBT PBT/PC PC/ABS PS PP PA POM PE Acrylic PVC TPR Example Material: PE Tip style: CV10 Maximum flow rate: 985 grams/second Note: Values in the table do not include reinforced materials or materials with fillers. SR16-7

8 Orifice Guidelines This table lists the normal gate orifice required to fill an average cavity of the listed wall thickness and surface area. The orifice diameter is based on the flow and freeze characteristics of each type of plastic at its normal processing conditions. It is not dependent on whether the cavity is fed by a hot or cold runner. Some of the listed wall thickness and surface area combinations are not applicable to all plastics because of the flow length to wall ratios of each material. Consult plastic supplier s processing recommendations. ue to the gate limitations of each hot runner nozzle, the actual gate may be slightly smaller or larger than the tabulated orifice. sq mm Orifice iameter Guideline mm(inch) P art Area Wall thickness mm/(inch) sq inch 0.75 (0.03) 1.00 (0.04) 1.5 (0.05) 1.50 (0.06) 1.75 (0.07).00 (0.08).5 (0.09).50 (0.10) 3.00 (0.13) 4.00 (0.16) , ) , , , , , , , , , , , , Material Factors Use tabulated orifice for PE, PP, PS, SAN and PUR. Use tabulated orifice x 1.15 for POM, PC, PPO and ABS. Use tabulated orifice x 1.30 for Acrylic, PA, PET, and PBT For non-reinforced PA, PET and PBT the minimum orifice diameter should be 4.0. For reinforced PA, PET and PBT the minimum orifice diameter should be 4.0. Part Area is total outside area and not the projected area of the part. Use tabulated orifice x 1.50 for PVC. SR16-8

9 Manifold Integration SR16 hot runner systems are designed with a preload between the thrust pads and the mold plates in the cold condition. As the manifold heats an additional sealing force is created. TCP T Thrust Pad Preload cold Center Locator The thrust pads are made of a low conductivity material and should only be replaced with an equivalent Synventive part. Rail height 65 Excessive contact with the mold will cause heat sinks and affect the system performance. Contact with the mold must be limited to specified areas. 6 Ø16 H6 Crush ring J Minimum rail height = 81 (thermal gates). Support ring nozzles do not line up with the sub-runners in the manifold in the cold condition. As the manifold heats up the manifold subrunner locations expand to the correct location. Variable T J TCP Top air gap Mold depth Top clamp plate escription T = Rail height (manifold) Minimum T = 10 (thermal gates) SR16-9

10 SR16 CV10 SR16 Series Manifold Nozzle Filled and unfilled materials. Easy orifice size changes by straight reaming Open flow bore Heat pipes for isothermal operation. 6 J Ø46 6 Contact Ø H6 Ø4 9.7 Ref The front face of the tip must be in contact with plastic. Cooling is required in the gate area. Heater Style J Min J Max Heater Qty Watts/ Volts (38 long) W/40 V (51 long) W/40V (each) SR16-10

11 Recessed gates are used to reduce vestige height above the part surface or keep the vestige below the part surface. For most materials CV10 vestige height is equal to.0 + orifice/. If the vestige height relative to the possible gate recess depth (h) is too great, use of a CV11 tip is recommended..0 + orifice orifice SR16 Series CV10 Recess Conical Recess h Orifice 4 Min contact Land Ø13 h Max = 3 = h h Recess Conical Recess Spherical Recess h Values in tables are for materials not having glass fibers. Consult Synventive for vestige height when using glass fillers Min contact Land R5 h Max = 3 = h(50-h) h Recess Spherical Recess SR16-11

12 CV10 Angled Mold Contour When gating onto an angled mold contour the vestige height may be increased depending on the angle. K is the increase in vestige height required to maintain 1.6 wall, 6 wall and/or 4 minimum contact. Land L 1.6 Min 6 Min E K 4 Min contact 6 ; K= 0 E = 1TAN L = - Orifice ia. TAN ; K= 4.TAN + - COS E = K + 1TAN L = + K - Orifice ia. TAN 6 ; K= 3TAN E = K + 1TAN L = + K - Orifice ia. TAN Angled Mold Contour SR16-1

13 SR16 CV11 SR16 Series Manifold Nozzle Filled and unfilled materials. More heat in gate area for semicrystalline materials 45 Heat pipes for isothermal operation. 6 Ø Land J Ø46 6 Contact H6 Ø4 9.7 Ref The front face of the tip must be in contact with plastic. Cooling is required in the gate area. Heater Style J Min J Max Heater Qty Watts/ Volts (38 long) W/40 V (51 long) W/40V (each) SR16-13

14 CV11 Recess Recessed gates are used to reduce vestige height above the part surface or keep the vestige below the part surface. Conical Recess Orifice h Orifice Land 30 4 Min contact Ø13 h Max = 3 = h h Recess Conical Recess Spherical Recess Orifice h d Values in tables are for materials not having glass fibers. Consult Synventive for vestige height when using glass fillers Land Orifice d (flat) Min contact d R5 h Max = 3 = h(50-h) h Recess Spherical Recess SR16-14

15 CV11 Angled Mold Contour When gating onto an angled mold contour the vestige height may be increased depending on the angle. K is the increase in vestige height required to maintain 0.13 land, 1.6 wall, 6 wall and/or 4 minimum contact. 6 Min L 1.6 Min E K 4 Min contact Orifice ia. 7 ; K= TAN E = L = Orifice ia. TAN 7 7 ; K= 4.TAN Orifice ia. - 1 Tan - COS E = K + 1TAN L = K - Orifice ia. TAN Angled Mold Contour 7 ; K= 3TAN E = K + 1TAN Orifice ia. L = K - TAN SR16-15

16 SR16 CV0 SR16 Series Manifold Nozzle Filled and unfilled materials. Easy orifice size changes by straight reaming. No tip witness mark on part. 6 Open flow bore. Heat pipes for isothermal operation. J Ø46 1 R 0.8 R Ø H6 Ø4 11. Ref 4.5 Cooling is required in the gate area. Heater Style J Min J Max Heater Qty Watts/ Volts (38 long) W/40 V (51 long) W/40V (each) SR16-16

17 CV0 Recess Recessed gates are used to reduce vestige height above the part surface or keep the vestige below the part surface. For most materials CV10 vestige height is equal to.0 + orifice/. If the vestige height relative to the possible gate recess depth (h) is too great, use of a CV11 tip is recommended. Conical Recess h orifice orifice 30 Orifice Land Ø13 h Max = 1.5 = h h Recess Conical Recess Spherical Recess h Values in tables are for materials not having glass fibers. Consult Synventive for vestige height when using glass fillers. Land R5 h Max = 1.5 = h(50-h) h Recess Spherical Recess SR16-17

18 CV0 Angled Mold Contour When gating onto an angled mold contour the vestige height may be increased depending on the angle. K is the increase in vestige height required to maintain 1.6 wall, wall or 6 wall thickness. Land 6 Min L Min 1.6 Min K 6 ; K= 0 L = - Orifice ia. TAN ; K= 4.TAN + - COS L = + K - Orifice ia. TAN 16 ; K= 1TAN COS L = + K - Orifice ia. TAN Angled Mold Contour SR16-18

19 SR16 CV1 SR16 Series Manifold Nozzle Filled and unfilled materials. No tip witness mark on part. More heat in gate area for semicrystalline materials. Heat pipes for isothermal operation. 6 R Ø Land J Ø46 R Ø4 H6 11. Ref 4.5 Cooling is required in the gate area. Heater Style J Min J Max Heater Qty Watts/ Volts (38 long) W/40 V (51 long) W/40V (each) SR16-19

20 CV1 Recess Recessed gates are used to reduce vestige height above the part surface or keep the vestige below the part surface. Maintain 0.13 land when machining gate recess. Conical Recess Orifice h Land Ø13 h Max = 1.5 = h h Recess Conical Recess Values in tables are for materials not having glass fibers. Consult Synventive for vestige height when using glass fillers. Spherical Recess Orifice h d Min contact Land R5 h Max = 1.5 = h(50-h) h Recess Spherical Recess SR16-0

21 CV1 Angled Mold Contour When gating onto an angled mold contour the vestige height may be increased depending on the angle. K is the increase in vestige height required to maintain 0.13 land, and/or 7 minimum wall. L Land 7 Min Land L 1.3 Min K 6 ; K= Orifice ia. 1.6 Orifice ia. - 1 TAN 6 16 ; K= 4.TAN + + TAN - 16 ; K= 1TAN COS COS L = 0.13 L = K - Orifice ia. TAN L = K - Orifice ia. TAN Angled Mold Contour SR16-1

22 SR16 VG1 Tapered SR16 Series Manifold Nozzle Filled and unfilled materials. Heat pipes for isothermal operation. Ø5 15 Tapered valve pin to eliminate gate flash. 6 Land J R0.13 Ø Pin protrusion Ø46 6 Contact Ø4 H6 9.7 Ref The front face of the tip must be in contact with plastic. Cooling is required in the gate area. Heater Style J Min J Max Heater Qty Watts/ Volts (38 long) W/40 V (51 long) W/40V (each) SR16-

23 VG1 Angled Mold Contour When gating on an angled mold contour the vestige height may be increased depending on the angle. 15 K is the increase in land required to maintain 1.6 wall, 6 wall and/or 4 minimum contact R0.13 Ø3.9 Land 6 Min 1.6 Min E K 4 Min contact 6 ; K= 0 E = 1TAN ; K= 4.TAN + - COS E = K + 1TAN 7 ; K= 3TAN E = K + 1TAN Angled Mold Contour SR16-3

24 SR16 VG1S Straight SR16 Series Manifold Nozzle Filled and unfilled materials. Heat pipes for isothermal operation. Ø5 30 Straight valve pin in gate for nonadjustable actuators and glass filled materials J R0.13 Ø4.999 Ø5.009 Land 0.13 Pin protrusion Ø46 6 Contact H6 Ø4 9.7 Ref The front face of the tip must be in contact with plastic. Cooling is required in the gate area. Heater Style J Min J Max Heater Qty Watts/ Volts (38 long) W/40 V (51 long) W/40V (each) SR16-4

25 VG1S Angled Mold Contour When gating on an angled mold contour the vestige height may be increased depending on the angle. 30 K is the increase in land required to maintain 1.6 wall, 6 wall and/or 4 minimum contact. R0.13 Ø4.999 Ø Land 6 Min 1.6 Min E K 4 Min contact 6 ; K= 0 E = 1TAN ; K= 4.TAN + - COS E = K + 1TAN 7 ; K= 3TAN E = K + 1TAN Angled Mold Contour SR16-5

26 SR16 VG3 Tapered SR16 Series Manifold Nozzle Filled and unfilled materials. No tip witness mark on part. Ø5 Heat pipes for isothermal operation. 15 Tapered valve pin to eliminate gate flash. 6 Land J R0.13 Ø Pin protrusion Ø46 1 R 0.8 R H6 Ø4 11. Ref 4.5 Cooling is required in the gate area. Heater Style J Min J Max Heater Qty Watts/ Volts (38 long) W/40 V (51 long) W/40V (each) SR16-6

27 VG3 Angled Mold Contour When gating on an angled mold contour the vestige height may be increased depending on the angle. 15 K is the increase in land required to maintain 1.6 wall, wall and/or 6 wall R0.13 Ø3.9 Land 6 Min Min K 6 ; K= ; K= 4.TAN + - COS.0 16 ; K= 1TAN COS SR16-7

28 SR16 VG3S Straight SR16 Series Manifold Nozzle Filled and unfilled materials. No tip witness mark on part. Ø5 Heat pipes for isothermal operation. 15 Straight valve pin in gate for nonadjustable actuators and glass filled materials J R0.13 Ø4.999 Ø5.009 Land 0.13 Pin protrusion Ø46 1 R 0.8 R H6 Ø4 11. Ref 4.5 Cooling is required in the gate area. Heater Style J Min J Max Heater Qty Watts/ Volts (38 long) W/40 V (51 long) W/40V (each) SR16-8

29 VG3S Angle Contour When gating onto an angled mold contour the vestige height may be increased depending on the angle. 15 K is the increase in land required to maintain 1.6 wall, wall and/or 4.0 minimum wall. R0.13 Ø4.999 Ø Land 1.3 Min Extension K 8 ; K= 0 E = 13TAN L = - Orifice ia. TAN 8 ; K= 4.75TAN COS - E = K + 13TAN L = + K - Orifice ia. TAN Angled Mold Contour SR16-9