INTRODUCTION

ADVANTAGES&DISADVANTAGES

The use of hot runner systems is increasing due to the fact that they provide a more efficient method of molding plastic parts. The cost savings can be substantial, and the part quality is very often much better than a cold runner system. With the increasing sophistication of today's plastic injection molds, the use of a hot runner system is becoming an industry standard. Many applications simply are not possible with the old standard sprue and cold runner system, and hot runners offer a great way to maintain uniform wall thickness and eliminate knit lines and flow lines. ot runners offer the following advantages! " #o loss of melt and thus less energy and work input. " $asier fully automatic operation. " %onger holding pressure, which leads to less shrinkage. " &horter cycles' cooling time no longer determined by the slowly solidifying runners' no no((le retraction required. " Machines can be smaller because the shot volume, around the runners, is reduced, and the clamping forces are smaller because the runners do not generate reactive forces since the blocks and the manifold block are closed. " &uperior quality because melt can be transferred into the cavity at the optimum sites. " )ates at the best position' thanks to uniform, precisely controlled cooling of the gate system, long flow paths are possible. " *ressure losses minimi(ed, since the diameter of the runners is not restricted. " +rtificial balancing of the gate system can be performed during running production by means of temperature control or a special mechanical system ,e.g. adjustment of the gap in a ring shaped die or use of plates in low channel-. The disadvantages are! " .onsiderably higher costs involved. " Much more comple/ to work with. " More work involved with the start up of the production cycle. " Thermal isolation from the hot runner manifold block is problematic. " The risk of decomposition and production stoppages in the case of materials with low thermal resistance. " More susceptible to breakdowns, higher maintenance costs ,leakage, failure of heating elements, and wear caused by filled materials-. " 0isk of thermal damage to sensitive materials because of long flow paths and dwell times, especially on long cycles. " More efficient temperature control required, because a nonuniform temperature cycle will cause different melt temperatures and thus nonuniform filling.

INSULATED RUNNERS 1nsulated runner moulds have oversi(ed passages formed in the mould plate. The passages are of sufficient si(e that, under conditions of operation, the insulated effect of the plastic ,fro(en on the runner wall- combined with the heat applied with each shot maintains an open, molten flow path. The main advantages of the insulated systems over the heated systems is the low cost, the ability to have thorough color changes, low pressure loss due to the large diameter runners, and that it introduces less heat to the partforming cavities. The moulds are designed such that a parting line is located along the melts flow channel. This parting line can easily be opened while the mould is still in the moulding machine. 2nce the melt has fro(en, this parting plane can be opened and the runner completely removed. This technique provides for very thorough color changes as well as for servicing the mould if the runner inadvertently free(es off. 1f this system is used, it is normally limited to low tolerance parts and commodity plastics such as polyethylenes, polypropylenes, and polystyrenes.

Internally heated manifold and nozzle. INTERNALLY HEATED RUNNERS

This system takes advantage of the insulating effect of the plastic melt to reduce heat transfer ,loss- to the rest of the mould. The second consists of a cartridgeheated manifold with interior flow passages. The manifold is designed with various insulating features to separate it from the rest of the mould, thus reducing heat transfer ,loss-. 1nternally heated systems eliminates most leaking problems, provides good isolation of the heater from the surrounding mould and provides good gate tip control. +s heaters are internal, there is no need for a separate manifold block, which must be heated and insulated from the surrounding mould with an air space. *lastic around the perimeter of the flow channel free(es against the colder mould, solidifies, and provides a thermally insulating boundary of plastic. This reduces the challenge with e/ternally heated hot runner systems of insulating the heat from the partforming cavity where you are trying to free(e the plastic. 1n addition, without the air gap surrounding the manifold in an e/ternally heated system, leakage concerns are virtually eliminated. Therefore, these systems are not recommended for use with thermally sensitive materials. 1n addition, the pressure drop during mould filling will be the highest of any of the hot runner molds per amount of material in the runner. The flow cross section can be increased to reduce the pressure but will result in increased residence time for the molten material. The development of the fro(en layer around the perimeter of the flow channel continues to create a challenge with regard to color changes.

Internally heated manifold and nozzle.

EXTERNALLY HEATED RUNNERS $/ternally heated systems have the ability to provide the lowest pressure drop compared to other systems, e/cept possibly for insulated hot runners. The flow channels are cylindrical in cross section and generally have a larger diameter than a cold runner system. The cylindrical flow channel is the most efficient shape for melt flow. +s cooling of the runner and regrind are not issues in the case of hot runners, a larger diameter is permissible. 3oth the larger diameter and the fact that there is no growing fro(en layer in the runner system, contribute to the relatively low pressure drop of these systems. This type of system may also provide the most homogeneous melt temperature of all hot runner systems. + melt injected at a temperature of 456 7. can be surrounded by a flow channel that is heated at 456 7.. Therefore the temperature gradient across the flow channel can be reduced, in contrast to an internally heated system, which is surrounded by a cold wall. 8isadvantages of an e/ternally heated runner system include the potential for leaking of molten plastic and the amount and location of the required heat from the heaters. 1mproper design or operation can result in plastic leaking between the no((le and the manifold. This leaking plastic can engulf the manifold, entombing it and destroying heaters, wires, and thermocouples. 1n

addition, the e/ternal heat source is in direct conflict with the cooling of the mould. The hot no((les often must be surrounded by an airspace, which helps insulate them from the cavity.

Externally heated manifold and nozzle. Advantages and disadvantages of hot !nne s"ste#s$

%AINTENANCE O& HOT RUNNER SYSTE%S

ot runner systems require a new level of e/pertise on the part of the mold maker. owever, this does not mean that it is overly complicated or highly speciali(ed. + well designed system is relatively free from maintenance, once it is properly installed. 1t can, and does happen, that mold makers become frustrated with hot runner systems and swear that they are too much trouble. This is usually due to the fact that the system is not properly installed or incorrectly operated in the molding process.