Hot Runner Guide. 1.Layout and Design. Hot Runner Guide. Company. Products. Technology. Application

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1 .ayout and Design Hot Runner Guide ompany roducts 00 ll rights reserved. Errors and omissions excepted. echnology pplication

2 ayout and Design he purpose of this Hot Runner Guide he Hot Runner Guide ayout and Design is intended to help everyone who designs feed systems for injection moulds or simply wants to find out about designing feed systems in the following way: èoverview of the Synventive hot runner product range èinsight into the layout of feed systems with hot runner technology èhelp to select suitable hot runner components Important note able of contents age... ll the information contained in these pages is based upon our current knowledge and experience gained from both theory and practise. However because of many factors outside our control they do not guarantee the suitability of our products for any particular application. lways consult Synventive for your specific application. Introduction he product range for individual hot runner solutions age 3 age Hot Runner omponents Nozzles Overview of nozzles series Key data of nozzles age... Manifolds Overview of the avalaible manifold series age 6... Flow ontrol Overview of the available actuators age 7... age 7... age 8... age 9... age 0... age... age... age 3... age 4... age... Material suitability Nozzles, size 03, open Nozzles, size 04, Nozzles, size 07, open Nozzles, size 07, valve gate Nozzles, size, open Nozzles, size, valve gate Nozzles, size 6, open Nozzles, size 6, valve gate Nozzles, size, open Nozzles, size, valve gate age 6... age 7... age 8... age 9... age... Hot Runner Design Designing the interface between cavity and runner Designing flow channel and interface to machine nozzle Defining the cavity gate diameter hat is the shot weight per nozzle used for? hermal expansion guide lines 00 ll rights reserved. Errors and omissions excepted. /

3 he indivdual hot runner solution from modular components. Hot Runner omponents. roduct Range Structure Each hot runner system is made from a set of componenst. he range of Synventive hot runner components is structured according to the work flow of how a) Hot runner nozzles Nozzle ranges with flow bores from 3. to mm, as single or manifold nozzles, make it possible to implement a very wide range of applications. b) Hot runner manifolds vailable in standard shapes I, H, X, and in any realisable custom shape, the ranges of manifolds cover all possible injection configurations and mould concepts. c) Melt flow control technology alve technology to control the melt flow has long been established in the form of valve gate nozzles. In addition, Synventive supplies Dynamic Feed, the innovative, realtime, online, highspeed regulation of the melt pressure in each cavity. a) b) c) d) d) onnections o customer specification or Synventive standard, Synventive hot runner systems are available prewired and prepiped. ll relevant connections electrical, thermocouple, hydraulic, pneumatic, coolant are brought out to the connection box and/or connection plate with appropriate connectors. e) Hot halves In the form of hot halves, the prestage of a complete half of a mould, hot runner systems are supplied completely mounted in mould plates, prewired, prepiped if required and fully adjusted. 3 e) 3. ustomer solution Using standard components almost any individual customised system can be created. 00 ll rights reserved. Errors and omissions excepted. /

4 Overview of nozzle series Nozzle style S E Nozzle size J Single nozzles hot sprue bush Manifold nozzles face fit Manifold nozzles screw fit 03 J = Ø 3.0 Standard flow boreø ) 03 S0 open 03 0 open 04 J = Ø S0 open E0 Nozzle series and gating type J = Ø 7.0 B... E open (N) B... M 07 E0 B N... S valve gate SR 8 J = Ø G... E open (N) G... M E0 G N... S S0... valve gate 6 J = Ø 6 GB... E open (N) GB... M 6 E0 GB N... S 6 S0... valve gate 6 E0 J = Ø E0 ) Depending on nozzle series and application different flow bore diameters are possible. 00 ll rights reserved. Errors and omissions excepted. 3 / E0

5 Key data of hot runner nozzles Nozzle key data Max. shot weight per nozzle (g) open valve gate Major dimensions Heater zones Nozzle style Nozzle series high a) b) medium c) low high a) b) medium c) low J D Xn No. ower () S 03 S0 04 S0 B... E B N... S G... E G N... S S0 GB... E GB N... S 6 S Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø4 Ø8 Ø7 Ø7 Ø40 Ø40 Ø40 Ø40 Ø48 Ø (N) B... M (N) G... M (N) GB... M Ø Ø Ø Ø Ø Ø Ø4 Ø8 Ø8 Ø7 Ø40 Ø , 7, E 07 E0 E0 6 E0 6 E0 E0 E Ø7 Ø Ø6 Ø6 & Ø Ø Ø & Ø Ø30 Ø40 Ø0 Ø40 Ø60 Ø Single Nozzles Single nozzles are hortunners with surface for machine nozzle directly on the nozzle head. For that these nozzles are also known as Hot sprue bushings.. Shot weight based on gating type and viscosity of melt. Major dimensions and heater zones Minimum and maximum value of nozzle length depend on the selected tip shape. Intermediate values can be found from the dimensional table of each nozzle series. ll nozzles are externally heated. he numbering of the heater zones starts at the nozzle tip and ends at the nozzle head. > 0 a s = a s < 60 a s iscosity of melt* a) high, MM EEK, ES, SU, EI, OM b) medium BS, SN, S, B, E, OM (opo),, E, O, S, /BS, /B c) low, E, S,, E J D S Single nozzle Manifold nozzle, face fit E Manifold nozzle, screw fit B M Manifold *at medium melt temperature and at a shear rate of 000 /s Xn minimal distance between nozzles 00 ll rights reserved. Errors and omissions excepted. 4 /

6 Manifolds vailable manifold series Nozzle size Nozzle series J max J max J max J max B B B N N N N M=37, M=6 6. D M=4, M=6 E M=0, M=80 F M=6, M=80 B (N) B... M K 07 E (N) G... M 8 8 E0 8 6 (N) GB... M E0 8 6 E0 8 E0 8 E Major dimensions I. Manifolds in standard shape 3. Manifolds in customised shape B J 4. Bridge manifolds H X 4 M M N: open nozzles : valve gate nozzles 00 ll rights reserved. Errors and omissions excepted. /

7 ctuators vailable actuators (N) B... M 07 E0 (N) G... M E0 (N) GB... M 6 E0 6 E0 E0 E0 Nozzle size Nozzle series H 08M H 408M H 408M H 4M N 3008B N 408M N 78M 0 N 78M 0 HZ QG H 4M ctuator bolted to the manifold. ctuator in mould plate 3. Dynamic Feed actuator pneumatic hydraulic 00 ll rights reserved. Errors and omissions excepted. 6 /

8 Material suitability: Open / alve gate nozzles, size 03, 04 ip shape ersion Gating Related nozzle series S S0 dditional suitability pplication polyolefines and amorphous all, use tool insert semicrystalline and cold runner amorphous and cold runner amorphous and cold runner all, use tool insert Material semicrystalline E EEK S E B E/ OM Homo OM opo amorphous MM BS S SN S E ES SU EI soft SM blends /BS /B thermopl. elastomers other properties EO/S/ EU fast cycle colorchange flame retardant mineral filed glasfiber suitable additional suitability not suitable ) consult Synventive ) use toolinsert 3) use cooled insert 4) direct gating or cosmetic surface ) coldrunner application 00 ll rights reserved. Errors and omissions excepted. 7 /

9 Material suitablity: Open nozzles, size 07 ip shape ersion Gating / 0 F / 0 / 0 / 0 X / 0 Related nozzle series 07 B... E (N) B... M SR 8 07 E0 Material suitability pplication Material dditives semicrystalline E EEK S E B E/ OM Homo OM opo amorphous MM BS S SN S E ES SU EI soft /BS SM /B thermopl. elastomers EO/S/ EU x : unfilled B: fillers : glass fibres D: flame retardants + : highly suitable x : suitable o : depending on application : unsuitable 00 ll rights reserved. Errors and omissions excepted. 8 /

10 Material suitablity: alve gate nozzles, size 07 ip shape ersion Gating / 0 / 0 / 0 X / 0 Related nozzle series 07 B N... S (N) B... M SR 8 07 E0 Material suitability pplication Material dditives semicrystalline E EEK S E B E/ OM Homo OM opo + x o o + x x o + x x o + x x o + x o o + x o o + x o o x x o x x o amorphous MM BS S SN S E ES SU EI soft /BS SM /B x x + + x x x x o + x x x + + x x x x o + x x x o o o o o o o thermopl. elastomers EO/S/ EU x x + o x x + o x : unfilled B: fillers : glass fibres D: flame retardants + : highly suitable x : suitable o : depending on application : unsuitable 00 ll rights reserved. Errors and omissions excepted. 9 /

11 Material suitablity: Open nozzles, size ip shape ersion Gating / 0 U / 0 F / 0 / 0 K / 0 / 0 S / 0 / 0 Related nozzle series G... E (N) G... M E0 6 E0 Material suitability pplication for all usual Material dditives semicrystalline E EEK S E B E/ OM Homo OM opo x x x x o x x o o x o o o amorphous MM BS S SN S E ES SU EI soft /BS SM /B x x x x x x x x o o o o o o o o x + x o thermopl. elastomers EO/S/ EU : unfilled B: fillers : glass fibres D: flame retardants + : highly suitable x : suitable o : depending on application : unsuitable 00 ll rights reserved. Errors and omissions excepted. 0 /

12 Material suitablity: alve gate nozzles, size ip shape ersion Gating / 0 / 0 S / 0 / X 0 Related nozzle series G N... S (N) G... M E0 6 E0 Material suitability pplication for when installation space is limited Material dditives semicrystalline E EEK S E B E/ OM Homo OM opo + x x x + x x x x o o o + x o o + x x o x x o x x o o o x o o x amorphous MM BS S SN S E ES SU EI soft /BS SM /B o o o o o o o o o o o o o o + + x x x + o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o + + o o + + o o + + o o x x o + o o o thermopl. elastomers EO/S/ EU o x x + o o x x + o + + o + x : unfilled B: fillers : glass fibres D: flame retardants + : highly suitable x : suitable o : depending on application : unsuitable 00 ll rights reserved. Errors and omissions excepted. /

13 Material suitablity: Open nozzles, size 6 ip shape ersion Gating / 0 U / 0 F / 0 / 0 K / 0 / 0 S / 0 / 0 Related nozzle series 6 GB... E (N) GB... M 6 E0 E0 Material suitability pplication for all usual Material dditives semicrystalline E EEK S E B E/ OM Homo OM opo x x x x o x x o o x o o o amorphous MM BS S SN S E ES SU EI soft /BS SM /B x x x x x x x x o o o o o o o o x + x o thermopl. elastomers EO/S/ EU : unfilled B: fillers : glass fibres D: flame retardants + : highly suitable x : suitable o : depending on application : unsuitable 00 ll rights reserved. Errors and omissions excepted. /

14 Material suitablity: alve gate nozzles, size 6 ip shape ersion Gating / 0 / 0 S / 0 / X 0 Related nozzle series 6 GB N... S (N) GB... M 6 E0 E0 Material suitability pplication for when installation space is limited Material dditives semicrystalline E EEK S E B E/ OM Homo OM opo + x x x + x x x x o o o + x o o + x x o x x o x x o o o x o o x amorphous MM BS S SN S E ES SU EI soft /BS SM /B o o o o o o o o o o o o o o + + x x x + o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o + + o o + + o o + + o o x x o + o o o thermopl. elastomers EO/S/ EU o x x + o o x x + o + + o + x : unfilled B: fillers : glass fibres D: flame retardants + : highly suitable x : suitable o : depending on application : unsuitable 00 ll rights reserved. Errors and omissions excepted. 3 /

15 Material suitablity: Open nozzles, size ip shape ersion Gating / 0 U / 0 / 0 K / 0 N / 0 S / 0 0 Related nozzle series E0 E0 Material suitability pplication for all usual Material dditives semicrystalline E EEK S E B E/ OM Homo OM opo x x o x x o o x o o o amorphous MM BS S SN S E ES SU EI soft /BS SM /B x x x x x x x x x + x o thermopl. elastomers EO/S/ EU : unfilled B: fillers : glass fibres D: flame retardants + : highly suitable x : suitable o : depending on application : unsuitable 00 ll rights reserved. Errors and omissions excepted. 4 /

16 Material suitablity: alve gate nozzles, size ip shape ersion Gating / 0 / 0 S / 0 / Related nozzle series E0 E0 Material suitability pplication for when installation space is limited Material dditives semicrystalline E EEK S E B E/ OM Homo OM opo + x x x + x x x x o o o + x o o + x x o x x o x x o amorphous MM BS S SN S E ES SU EI soft /BS SM /B o o o o o o o o o o o o o o + + x x x + o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o + + o o + + o o + + o o x x o thermopl. elastomers EO/S/ EU o x x + o o x x + o + + o + x : unfilled B: fillers : glass fibres D: flame retardants + : highly suitable x : suitable o : depending on application : unsuitable 00 ll rights reserved. Errors and omissions excepted. /

17 Designing the interface between cavity and runner hoose gating type riteria: èoptimum mould filling by optimum number, position, shape and size of gates èuse best mould concept for an economic production hoose nozzle type riteria ègating type needed èmaterial suitability of selected nozzle type Direct gating Gating on cold sub runner Gate mark on part or sub runner Shape of nozzle tip Gating of nozzle tip H N hrough bore tips Open estige with wittness mark H short through bore tip Dimensions H Nozzle length, hot Hot runner gateø H estige in a dimple with wittness mark H H U F like with increased contact surface like with dimple H H H Sprue and wittness mark estige with / without dimple H H H H H H H Blind bore tips K S like U with dimple through bore tip with sprue like with sprue like with increased contact surface slim tip with sprue extended blind bore tip Open with torpedo alve gate B Sprue 00 ll rights reserved. Errors and omissions excepted. 6 /

18 Designing flow channel and interface to machine nozzle hoose the nozzle riteria: èkind of hot runner system and gating configuartion èmaximum shot weight per nozzle hoose manifold and / or inlet bushing riteria èssociated nozzles actuators etc. ègating configuration riteria èmachine èrocess Nozzle size Nozzle style hickness x width of manifold Machine nozzle contact 03 J = Ø 3 S Single nozzle 04 J = Ø 4 07 J = Ø 7 J = Ø 6 J = Ø 6 J = Ø J B M E Manifold nozzle, face fit Manifold nozzle, screw fit Manifold D E F M = 37 M = 6 M = 4 M = 6 M = 0 M = 80 M = 6 M = 80 Dimensions J D H M M B Flow boreø Nozzle length, hot Ø cut out, front Hot runner gateø Manifold thickness Manifold width Manifold cut out, right (above) Manifold cut out, left (below) D hoose flow control device riteria èselected gating type = valve gate èdditional pressure control inside flow channel alve gate components Melt pressure control Nozzle head for single axis valve gate nozzles ctuator bolted to manifold ctuator in mould plate Flow valve module B 00 ll rights reserved. Errors and omissions excepted. 7 /

19 he cavity gate (a) is the last section of the flow channel where it gates into the cavity. Number, size, shape and positions of the gates inside the cavity have great influence on the filling of the cavity and the features of the moulded part. Hot Runner Guide Defining the cavity gate diameter Illustrations simplified, schematically drawn and not to scale. For hot runner nozzles two case can apply:. Gating on cold sub runner hen gated via a cold sub runner the hot runner gate at the nozzle tip is just another section of the flow channel of the complete feed system. he gate mark on the cold sub runner does not have to meet very high demands. herefore the hot runner gate can as big as possible. a) avity gate diameter (mm) 4.0 a) all thickness (mm) 3.0. Direct gating on the part surface hen gated directly on the part surface the hot runner gate is also the cavity gate which has to meet very high demands related to appearance and quality. he gate mark quality is influenced by several factors: B..0. àgate diameter àall thickness of the moulded part àart weight àype of plastic àflow rate àemperature control around the gate àgeometry of moulded part o choose the cavity gate diameter the graph shown on the right can be used as a guide line. It is based on practical experience as well as theoretical studies. hey are valid for non filled materials. For a specific application, please always consult Synventive x x 0 x 00 x Shot weight per nozzle (g) Boundary conditions for the graph: àdirect gating via hot runner àhermoplastic material àno fillers or additives àmedium melt temperature àmedium injection time Example B Shot weight per nozzle: all thickness: 00 g. mm General remaks For reinforced ratios higher than % the gate diameter should be be increased by 0 %. Gate diameter: found in the graph:.6 mm If the gate is too small: àhigh shear rate àhigh pressure loss àmuch heat caused by friction chosen Standard gate for. : chosen Standard gate ffor. + 30% GF:.7 mm 3.0 mm If the gate is too big: àhigh vestige àbad gate mark quality 00 ll rights reserved. Errors and omissions excepted. 8 /

20 hat is the shot weight per nozzle used for? he term maximum shot size per nozzle denotes the performance capacity of a hotrunner nozzle, that is, the maximum quantity of plastic melt that can pass through the nozzle during operation without damaging the nozzle or plastic material. he reason performance capacity is specified in terms of weight rather than volume flow is that it is more readily understandable to the user, who has usually received information on the weight of the moulded parts to be produced. = + + How to find the shot weight per nozzle () is shown on the right for three different applications.. Several parts per nozzle èmulti cavity mould with single nozzle ègating on cold sub runner èshot weight per nozzle = arts + runner. One part per nozzle èmulti cavity mould with manifold system èdirect gating on to the part èshot weight per nozzle = part 3. Several nozzles per part èsingle cavity mould with manifold system èdirect gating on the part èshot weight per nozzle = Section of the cavity which is filled by one nozzle = = he maximum shot size that can be achieved depends on several factors: àinjection time àype of plastic: viscosity, additives, etc. àrunner length/diameter àmaximum permitted pressure loss àresidence time 3 hen the above factors are taken into consideration, conflicting requirements may arise in some cases. Flow channel as big as possible: low pressure loss low shear rate Flow channel as small as possible: low residence time good melt exchange = = he values for the maximum shot weight of Synventive nozzle have been derived from practical experience as well as theoretical studies. hey are valid for non filled materials. For a specific application, please always consult Synventive. 3 3 = 00 ll rights reserved. Errors and omissions excepted. 9 /

21 hermal expansion guide lines During production the temperature of the hot runner system will be much higher than the mould. his temperature difference results in a higher thermal expansion of the hot runner manifold relative to the mould. his difference must be allowed for in the design of the hot runner to ensure correct alignment accuracy for sealing and thus correct function of the hot runner system. ll guidelines shown here are based on the following criteria. è.3, =.9 0 6/K (Standard) è.36, = /K he information shown here refer mainly to I proudcts. For products please refer direclty to the technical documentation or consult Synventive. X M Z old Hot = = Room temperature > = Melt temperature = Mould temperature. djusting the nozzle length hen at operating temperature the nozzle must fit accurately into the mould cut out. It must not touch the mould except for the fitting diameter and should be the correct length so that it is neither protruding nor standing back. his is achieved by designing the nozzle shorter, considering the expansion when it is heated. he nozzle length in the catalogue always refers to the hot condition which should also be the mould dimension at operating temperatures. Example = 0 = 6 mm. reload on the manifold when face fit manifold nozzles are used he sealing interface between face fit manifold nozzles and the manifold depends upon the correct load applied by the manifold due to thermal expansion. his is achieved by having the an expansion gap between the manifold support pads and back plate when cold to allow for thermal expansion but also to apply the correct load when the system is hot. he correct expansion gap Z can be calculated by using the rules shown on the right. Example = 0 M = 0 mm rt = Z = 0 mm 6 mm.008 =.48 mm = mm 3 old rt = rt = rt + ( ) old Qe Z Hot rt = Qe Hot Qe Qe = +( ) = = K ( ) M Z (mm) for = (mm) Steel Ratio of pitch dimension and nozzle length for screw fit nozzles he thermal expansion of the manifold makes the nozzle head of screw fit manifold nozzles move while the nozzle tip is fixed inside the mould cut out. his leads to the nozzle being bent. In order to allow the nozzle to bend without being damaged the nozzle must be of a certain minimum length. s shown on the right, the minimum lenght of a screw fit manifold nozzle must be half the size of its pitch dimension. Example X = 00 mm = min. 0 mm 3 Z = (M ) 0.0 mm Z = M (Qe) 0.0 mm X 3 X (mm) acceptable incorrect! X (mm) 00 ll rights reserved. Errors and omissions excepted. /

22 00 ll rights MKRM.BR. reserved. Errors GB and..hrgd0 omissions 00 excepted. ll rights reserved. Errors and omissions excepted.