Professional Documents
Culture Documents
Status
Hot runner molds provide advantages vs. cold runner systems, among which the obvious ones are: less material
to plastify leading to shorter cycles and no (or minimum) regrind. On the other hand, hot runner molds add complexity and
costs. They often require maintenance and skilled molding operators.
• Drooling around the gate, which potentially can be responsible for bad
surface aspect and deformation.
The critical objective is to allow the part to freeze at the gate outlet and
remain molten at the gate inlet over a distance which represents a fraction
of a millimetre. This requirement is exceedingly difficult to accomplish with Cold slug trap
direct gated parts using hot tip hot runner systems.
The use of a hot runner combined with cold sub-runners will achieve this
goal, also contributing to a more robust process (Figure 2). The cold slug Fig. 2 – Typical layout of a combination
trap in front of the hot nozzle will catch any frozen or degraded material. of Hot Nozzle with cold sub runners
Key criteria for selecting a Hot Runner System
The following is a summary of typical weaknesses observed in Hot Runner System which require improvement :
• Dead spots (1)
• In hot manifold flow channel
• At tip of heated nozzle
• High heat loss
• Inappropriate temperature controls (including thermocouple location)
• Gate & channel dimension not allowing insufficient Flow & Hold Pressure Time
• Ease of maintenance (purging, heating system.)
• Poorly trained operators
Dead Zone or Hold-up Spots Dead Zone or Hold-up Spots Dead Zone or Hold-up Spots in
in manifolds of internally heated torpedo valve gate (direct gating)
Channel Corners in the Hot Manifold
system (direct gating) Valve gate design requires special
could be a concern as they may result The dead zone on the far side of the attention relative to the inherent dead zone
in a pressure drop in the channel but torpedo may cause polymer stagnation present on the far side of the pin where
more dramatically in the « dead zone » and degradation. (Fig. 4a). polymer can stagnate (Fig. 4b).
if not properly designed. Hot Runner
manufacturers offer a wide range of flow
optimized geometries in corners to avoid
Hold-up spots.
Not recommended ? ?
?
Acceptable
Optimum
Fig. 3 – Typical Channel geometries Fig. 4a – Torpedo design Fig. 4b – Valve gate design
Gate freeze-off in valve gate system with fast freezing polymers. (direct gating)
In order to achieve good dimensional fact, cannot push this solidified mass of valve pin to push this material into the
control and/or obtain good surface material into the (semi)-solidifed part.The part upon closing. When forced to do this,
appearance, the ‘optimum’ SFT required end result is a ‘puck’ of frozen material problems become apparent with the part
to obtain (or get close to) freeze-off across that stands proud of the surface of the (dimensional issues, poor surface, etc.).
the wall section of the part will very often part, sometimes by as much as several
also result in freeze-off of the material in millimeters). It’s a no-win situation unless the molder
the gate itself (in front of the retracted is made aware of this potential issue and
valve pin). Many valve-gate systems The only solution is to significantly reduce agrees that a gate projection is acceptable.
cannot deliver sufficient pressure to force SFT so that the part wall, and material
the closing of the valve pin against this in front of the retracted valve pin is still
(semi-) frozen mass of material, and in semi-molten, which then allows for the
Copyright © 2010 E.I. du Pont de Nemours and Company. All rights reserved. ® DuPont registered trademark. ™ DuPont trademark
« Dead Zone » or «Hold-up spots» in nozzles (direct gating)
Same challenges also apply to the nozzle tips where a fully streamlined design is mandatory to avoid degradation possibly leading to surface
aspect problems and brittleness. Optimized streamlining reduces the necessary time when changing material color. (Fig. 7)
Gate tip design, where molten plastic is insulating the tip, should be avoided (see below Fig. 6).
To limit restriction and consequent pressure drops, externally heated hot nozzles are preferred versus Internally heated (Fig. 5) and heat
conductive nozzles (not shown).
Fig. 5 – Internally heated Fig. 6 – Self insulated Fig. 7 – Hot Gate design with mini torpedo
Torpedo with cartridge. Nozzle tip. (when direct gating).
Side-gating systems on the vertical Combination of Hot runner with cold runner
part wall (direct gating – special case) Gate freeze-off in Hot Runner Systems is less predictable than with a cold runner
By design the part shears away from the hot approach. It is one reason why it is recommended to use them in combination
edge-gate during ejection, potentially leaving a with cold sub- runners :
semi-frozen slug in the gate orifice. This slug either
Open nozzle Mini torpedo in open nozzle
gets injected with the next shot (creating a surface
Prefered for glass reinforced Mini torpedo in open nozzle
defect) or freezes-off completely, resulting in a materials
plugged gate and subsequent risks of short shots
and potential flash in other (open) cavities.
The inscribed diameter «D» of the tunnel next to the gate must
be at least 1,2 × the part thickness. The gate shown on the right
side in Fig. 9 is not recommended for crystalline materials.
Copyright © 2010 E.I. du Pont de Nemours and Company. All rights reserved. ® DuPont registered trademark. ™ DuPont trademark
System temperature control
Inappropriate layout of the heating system
can lead to over heating (i.e if hot sprue is
not properly insulated or the position of the
thermocouple is not correct). Further more,
contact between the hot runner system and
the mold should be minimized in order to limit
heat losses that are the main cause for poor
temperature distribution (Fig. 10).
Thermocouple
Temperature control
of the cavity
Another challenge with a direct hot
runner nozzle is the consequent
non-uniformity of the cavity wall
temperature created by the very close
location of the nozzle.
Semi-crystalline require well selected hot runner technology to take advantage of productivity benefits
The information provided herein corresponds to our knowledge on the subject at the date of its publication. for any testing you may need to conduct to determine for yourself the suitability of a specific material
This information may be subject to revision as new knowledge and experience becomes available. The for your particular purposes. Since DuPont cannot anticipate all variations in actual end-use conditions
data provided fall within the normal range of product properties and relate only to the specific material DuPont makes no warranties and assumes no liability in connection with any use of this information.
designated; these data may not be valid for such material used in combination with any other materials or Nothing in this publication is to be considered as a license to operate under or a recommendation to
additives or in any process, unless expressly indicated otherwise. The data provided should not be used infringe any patent rights. L-14496
to establish specification limits or used alone as the basis of design; they are not intended to substitute
Copyright © 2010 DuPont. All rights reserved.The DuPont Oval Logo, DuPont™,The miracles of science™ and all products denoted with ® or ™ are registered trademarks or trademarks of E. I. du Pont de Nemours and Company or its affiliates.
For more details on every aspect on moulding with Delrin®, Zytel®, Rynite®, Crastin® please refer to the Moulding Manuals.