Suppliers of valve-gate nozzles and related hot-runner components continue to expand and improve options for molders in their perennial quest to boost performance and lower costs.
INCOE
The innovations include new versions of Incoe’s miniaturized, hydraulically actuated HEM valve-gate cylinders that require no cooling for most applications. Bott said the new HEM cylinders require less milled area, which “reduces machining time and enhances mold support.”
The smaller configuration will increase mold- design freedom, reduce maintenance and allow sequential actuation within tighter pitches, he said. The company did not disclose product dimensions.
Incoe also is adding smaller sizes to its Slim-Flo line of single-body heaters, which will offer two zones of temperature control within a reduced diameter and won’t require slots to be machined for heater leads. Bott said there are several advantages:
• The smaller diameter and simplified geometry will permit water lines to be closer to the nozzles.
• The heaters will have a tighter pitch centerline to the centerline of nozzles.
• The smaller configurations suit reverse-ejection applications that require long nozzles and that should not have heater leads near an ejector plate.
With an eye toward reducing both the amount and complexity of machining required for marrying a hot-runner system to a mold, Incoe supplies engineering support to simplify design, Bott said. It also is increasing hot-runner design automation to speed development and delivery of systems.
The goal, Bott said, is production of a “robust hot-runner system” that minimizes lifetime operating costs.
MANNER
Männer, a maker of small valve-gated nozzles for high-volume products, as well as high-cavitation molds, has extended its Slimline options to include the Slimline 6.5 hot-runner nozzle, with a rated nozzle diameter of 6.5mm. The previous smallest version was the 8mm Slimline 8.
The Slimline 6.5, which the company unveiled in October at Fakuma, optimizes molding of PP and HDPE. The nozzle is engineered for resistance to wear and pressure, the company said, and is suitable for processing high-performance materials. Its size facilitates close cavity spacing and makes it appropriate for applications with tightly spaced configurations such as direct injection close to the core or inner injection for high-cavitation molds.
Männer is, with Synventive and another supplier, Thermoplay, part of Barnes Molding Solutions. Synventive’s Bill Rousseau, director of applications and technical services, said that “there are a lot of opportunities for collaboration between the companies,” as well as “increased sharing of knowledge, resources and intellectual property.” He declined to discuss R&D projects but said that new user interfaces for the various control systems of each company “all have a similar layout, look and feel, making it easier for users familiar with one to operate another.”
HUSKY INJECTION MOLDING SYSTEMS
Husky Injection Molding Systems is focusing on valve-gate longevity. Ultra Helix nozzles can withstand millions of molding cycles. “Molders see benefits in uptime and direct repair cost and reduce the risk that their customers may reject parts,” said Sean Hoy, VP Hot Runners, Americas.
Husky is expanding the line this year with the Ultra Helix 250 T2, for difficult-to-access gate locations and small parts. “This will be our smallest valve-gate nozzle, with a 12mm bore, and will … provide customers with excellent gate life and longevity along with low lifetime cost,” Hoy said.
The company did not disclose details about performance. In a recent Husky video, however, a spokesman described the company’s then- smallest Ultra Helix 350 nozzle, with pitch spacing of 18mm, as capable of up to 5 million cycles due to its gate alignment and guide technology.
This year, Husky also plans to launch an Ultra Helix Packaging valve gate. “The tip is designed for the high throughput and fast cycles typical of thin-wall packaging,” Hoy explained. “Gate renewal will be as easy as replacing the nozzle tip without the need for cavity insert rework.”
The company is enhancing its Ultra Helix nozzles to facilitate fast color changes. “Color change in some applications can be a significant cost in materials and machine time to properly flush a previous color from the manifold,” Hoy said. “Our customer will see significant improvement in color-change performance with the Ultra Helix valve gate.”
HRSFLOW
HRSflow has developed space-saving actuating cylinders for valve gates to allow construction of compact stack molds that have thinner plates.
The company said that low-profile stack molds can be configured by staggering the actuating cylinders to the side of the nozzles and using rocker levers to transmit movement from the cylinders to the needles and tips of the hot runners.
Mold construction heights are “much lower” than when cylinders and needles are aligned, HRSflow said. Additionally, plate thickness can be as little as 212mm for in-line nozzles and 132mm for offset nozzles, according to HRSflow.
“Stack molds with a lower height often allow the use of smaller injection molding machines, which then lead to much lower running costs. In this way, our ‘Compact Stack Tool’ technology helps to make the operation of stack molds even more economical,” said Stephan Berz, VP of sales.
For use with PP, ABS and PC/ABS, the technology targets large parts such as bumper fascia, bins and pallets.
GUNTHER
Günther Heisskanaltechnik GmbH, Frankenberg an der Elder, Germany, is expanding the BlueFlow range this year and will be presenting new hot-runner manifold technologies at the K show in October. Horst-Werner Bremmer, head of technical consulting and sales at Günther, did not reveal details. He noted, however, that the company already supplies products with capabilities such as side gating with separately controlled nozzles and direct gating with shot weights down to 0.004 gram.
In the U.S., LHR Technical Service represents Günther.
Pat Toensmeier, contributor
Contact:
HRSflow, Byron Center, Mich., 616-228-6900, www.hrsflow.com
Husky Injection Molding Systems Ltd.,
Bolton, Ontario, 905-951-5000, www.husky.ca
Incoe Corp. USA,
Auburn Hills, Mich., 248-616-0220, www.incoe.com
LHR Technical Service LLC, Sandwich, Ill., 630-802-7755, www.guenther-hotrunner.com
Manner USA Inc.,
Lawrenceville, Ga., 770-449-1820, www.maenner-group.com
