Hot Runner Guide Layout and Design C Company T Technology P Products A Application Hot Runner Guide Layout and Design The purpose of this Hot Runner Guide C P T A The Hot Runner Guide - Layout and Design is intended to help everyone who designs feed systems for injection molds or simply wants to find out about designing feed systems in the following way: à Overview of the Synventive hot runner product range à Insight into the layout of feed systems with hot runner technology à Help to select suitable hot runner components Important note All 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. Always consult Synventive for your specific application. Table of Contents Introduction Page 3 .................................................. The product range for individual hot runner solutions Hot Runner Components Nozzles Page 4 .................................................. Overview of nozzles series Page 5 .................................................. Key data of nozzles Manifolds Page 6 .................................................. Overview of the avalaible manifold series Flow Control Page 7 .................................................. Overview of the available actuators Material Suitability Page 8 .................................................. Nozzles, size 06, open / valve gate Page 9 .................................................. Nozzles, size 09, open / valve gate Page 10 .................................................. Nozzles, size 12, open / valve gate Page 11 .................................................. Nozzles, size 16, open / valve gate Page 12 .................................................. Nozzles, size 22, open / valve gate Hot Runner Design Page 13 .................................................. What is the shot weight per nozzle used for? Page 14 .................................................. Thermal expansion guide lines © Synventive Molding Solutions 2014-12-17 CAT-14-0001_EN-REV03 2 / 14 All rights reserved. Errors and exceptions excepted. Hot Runner Guide The indivdual Hot Runner solution from modular components Hot Runner Components C P T A 1 Product Range Structure Each hot runner system is made from a set of components. The range of Synventive hot runner components is structured according to the work flow of how a) Nozzles Wide range of nozzles to suit most applications. b) Hot Runner Systems 2 a) b) Available in standard shapes - I, H, X, Y - and in any realisable custom shape, the ranges of manifolds cover all possible injection configurations and mold concepts. c) d) c) Melt Flow Control Technology Utilizing valve gate technologies, Synventive provides solutions from traditional SVG to activeGate™ technology to meet the needs of the most challenging applications. d) Connections To customer specification or Synventive standard, Synventive hot runner systems are available pre-wired and pre-piped. e) Hot Halves Hot runner systems are supplied completely mounted in mold plates, pre-wired, pre-piped if required and fully adjusted. © Synventive Molding Solutions 2014-12-17 e) 3 CAT-14-0001_EN-REV03 3 / 14 All rights reserved. Errors and exceptions excepted. Hot Runner Guide Overview of Nozzle Series C P T A Nozzle style Nozzle size J Sprue bushing (thermal gate) Single valve gate nozzles (pneumatic / hydraulic) Threaded nozzles (thermal gate / valve gate) J=Ø6 Ø6 06 06 S 06 E01 J=Ø7 07 CBN S pneumatisch J=Ø9 09 09 S J=Ø12 12 12 S GA N… S 12 SV pneumatisch hydraulisch GB N… S 16 SV pneumatisch hydraulisch 12 E01 J=Ø16 16 16 S 12 09 E01 16 E01 16 16 E02 J=Ø22 22 22 S 16 22 E01 22 22 E02 © Synventive Molding Solutions 2014-12-17 CAT-14-0001_EN-REV03 4 / 14 All rights reserved. Errors and exceptions excepted. Hot Runner Guide Key Data of Hot Runner Nozzles Nozzle key data Max. shot weight per nozzle (g) Nozzle size mediumb) lowc) higha) mediumb) lowc) S E 06 S 09 S 12 S 16 S 22 S CBN… S GAN … S 12 SV GBN … S 16 SV pneumatic pneumatic hydraulic pneumatic hydraulic 06 E01 09 E01 12 E01 16 E01 16 E02 22 E01 22 E02 valve gate ………………… ………………… ………………… ………………… ………………… ………………… ………………… ………………… ………………… ………………… 30 70 500 1000 1500 - 70 120 800 1500 2500 - 120 250 1500 2500 5000 - - - - 10 80 80 250 250 50 150 150 600 600 80 300 300 1500 1500 Ø6 Ø9 Ø12 Ø16 Ø22 Ø7 Ø12 Ø12 Ø16 Ø16 ………………… ………………… ………………… ………………… ………………… ………………… ………………… 30 70 500 1000 700 1500 1200 70 120 800 1500 1000 2500 2000 120 250 1500 2500 2000 5000 3500 10 40 100 500 100 800 300 45 80 250 800 200 1200 800 80 200 500 1500 400 2000 1500 Ø6 Ø9 Ø12 Ø16 Ø16 & Ø12 Ø22 Ø22 & Ø18 Nozzle series T A Major dimensions higha) open C P J L D Xn 60…200 60…400 60…650 96…627 96…627 33.5…243.5 48…297 48…297 48…380 96…627 Ø20 Ø27 Ø35 Ø50 Ø60 Ø27 Ø40 Ø40 Ø48 Ø50 - 60…200 60…400 96…627 96…627 196…647 96…627 196…647 20 27 Ø40 Ø50 Ø40 Ø60 Ø50 20 30 46,5 57 57 67 67 - S Viscosity of melt* > 150 Pa s Shot weight based on gating type and viscosity of melt PC, PMMA PEEK, PES, PSU, PEI, POM L = 60...150 Pa s b) medium ABS, SAN, ASA, PBT, PET, POM (Copo), PA, PPE, PPO, PPS, PC/ABS, PC/PBT 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. a) high < 60 Pa s B M A J c) low PP, PE, PS, LCP, TPE E D L * at medium melt temperature and at a shear rate of 1000 1/s © Synventive Molding Solutions 2014-12-17 CAT-14-0001_EN-REV03 5 / 14 Xn - minimal distance between nozzles for thermal gate All rights reserved. Errors and exceptions excepted. Hot Runner Guide Manifolds Available manifold series V-37 Nozzle size Nozzle series M= 37 V-42 M1= 36 J2 max. NT V A M= 42 V-45 M1= 50 J2 max. B NT V A M= 45 V-50 M1= 50 J2 max. B NT V A M= 50 VE M1= 60 J2 max. B NT V A M= 50 T A VF M1= 80 J2 max. B NT V A C P M= 65 M1= 80 J2 max. B NT V A B 06 06 E01 …… 09 09 E01 …… 12 12 E01 …… 18 12 20 20 22 22 20 20 16 16 E01 16 E02 …… …… 18 12 20 20 22 22 20 20 18 12 20 20 22 22 20 20 22 22 E01 22 E02 …… …… 18 12 20 20 22 22 20 20 18 12 20 20 22 22 20 20 10 10 10 15 10 NT: 12 10 15 12 10 V: Open nozzles B J2 Major dimensions 12 15 Valve gate nozzles A M M1 © Synventive Molding Solutions 2014-12-17 CAT-14-0001_EN-REV03 6 / 14 All rights reserved. Errors and exceptions excepted. Hot Runner Guide Actuators HYC4520M PNC3008B PNC4508B PNC6018B PNC4508M PNC6018M PNC7518M HYZ3908 QCVG16 VP4008P VP8016P ELA4308P ELA5708P ELA8708P ELA8716P electrical HYC4018M Nozzle size Nozzle series hydraulic HYC4016M Available actuators pneumatic T A HYC2508M a C P Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc 06 06 E01 ……… 37 - - 42 - - 57 - - - - 55 - 45 60 - - - 09 09 E01 ……… 37 - - - 61 - 57 - - 53 - 55 - - - 90 90 - 12 12 E01 ……… - 57 96 - - - - - 90 - 100 - 97 - - - - - 16 16 E01 16 E02 ……… ……… - - 57 140 - - - - - 90 - 100 - 97 - - - - - - - 57 140 - - - - - 90 - 100 - 97 - - - - - 22 22 E01 22 E02 ……… ……… - - 63 140 - - - - - 90 - 100 - 97 - - - - - - - 63 140 - - - - - 90 - 100 - 97 - - - - - Actuator bolted to the manifold - Xc Xc Actuator in mold plate Actuator with backing plate Electrical actuator in mold plate Xc Xc © Synventive Molding Solutions 2014-12-17 CAT-14-0001_EN-REV03 7 / 14 All rights reserved. Errors and exceptions excepted. Hot Runner Guide Material suitability: Nozzles, size 06 C P T A Illustrations simplified, schematically drawn and not to scale. All dimensions in mm. Tip shape Version Gating Related nozzle series 06 K 01 P K 01 N K 01 T Y 10 T W 10 T Y 10 V W 10 V ● ● ● ● ● ● ● L 06 E01 Parameters Extension (F) Gate Ø (H) 6 1.2 - 2.0 6 6 - - - - 1.2 - 2.0 1.2 - 2.0 0.8, 1.2, 1.6 0.8, 1.2, 1.6 1.6 0.8, 1.2, 1.6 direct on part for semi-crystalline materials, or cold runner applications direct on part, cooled toolinsert recommended Material suitability Application thermopl. elastomers blends amorphus thermoplastics semi-crystalline thermoplastics Material cold runner applications cold runner applications, high filled material, TPE, TPU cold runner applications, semicrystalline materials direct on part for semi-crystalline materials, or cold runner applications direct on part cooled + hardened toolinsert recommended fast cycle cosmetic gate wear resistant PE PP PEEK PPS PET PBT PA6 PA6.6 PA4.6 PPA POM Homo POM Copo LCP PMMA ABS ASA SAN PS PPE PC PES PSU PEI SMA PVC soft PC/ABS PC/PBT PA/ABS TPE-O/S/V TPE-U Disclaimer: For resins not mentioned in the overview or specific applications please consult Synventive. Highly Suitable © Synventive Molding Solutions 2014-12-17 Suitable CAT-14-0001_EN-REV03 8 / 14 Consult Synventive Not Suitable All rights reserved. Errors and exceptions excepted. Hot Runner Guide Material suitability: Nozzles, size 09 Tip shape Version Gating 09 E01 Parameters Extension (F) Gate Ø (H) Material suitability Application thermopl. elastomers blends amorphus thermoplastics semi-crystalline thermoplastics Material K 01 N K 01 T S 10 T W 10 T ● ● ● ● ● T A Illustrations simplified, schematically drawn and not to scale. All dimensions in mm. S 10 V S 25 V W 10 V W 25 V ● ● ● ● L Related nozzle series 09 K 01 P C P 10 10 10 0, 10 2.0, 2.5 2.0, 2.5 2.0, 2.5 1.5, 2.0, 2.5 cold runner applications, semi-crystalline materials direct on part for semi-crystalline materials, or cold runner applications cold runner applications cold runner applications, high filled material, TPE, TPU - 0, 10 0, 10 1.2, 1.6, 2.0, 2.5 2.5 2.5 direct on part, cooled toolinsert recommended direct on part for semi-crystalline materials, or cold runner applications direct on part for semi-crystalline materials, or cold runner applications - - 1.5, 2.0, 2.5, 3.0 1.5, 2.0, 2.5 direct on part cooled + hardened toolinsert recommended direct on part for amorphous materials, cooled + hardened toolinsert recommended fast cycle cosmetic gate wear resistant PE PP PEEK PPS PET PBT PA6 PA6.6 PA4.6 PPA POM Homo POM Copo LCP PMMA ABS ASA SAN PS PPE PC PES PSU PEI SMA PVC soft PC/ABS PC/PBT PA/ABS TPE-O/S/V TPE-U Disclaimer: For resins not mentioned in the overview or specific applications please consult Synventive. Highly Suitable © Synventive Molding Solutions 2014-12-17 Suitable CAT-14-0001_EN-REV03 9 / 14 Consult Synventive Not Suitable All rights reserved. Errors and exceptions excepted. Hot Runner Guide Material suitability: Nozzle size 12 Tip shape Version Gating Related nozzle series 12 12 E01 (H) Material suitability Applications thermopl. elastomers blends amorphus thermoplastics semi-crystalline thermoplastics Material S 01 T W 10 T W 10 V W 25 V ● ● ● ● ● T A Illustrations simplified, schematically drawn and not to scale. All dimensions in mm. V 10 V V 25 V S 10 V S 25 V ● ● ● ● L Parameters Extension (F) Gate Ø K 27 N C P 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 2.2 , 2.5, 2.8, 3.2, 3.6, 4.0 2.1, 2.4, 2.7, 3.0, 3.3, 3.6 cold runner applications direct on part for semi-crystalline materials, or cold runner applications - - 2.1, 2.4, 2.7, 3.0, 3.3, 3.6 direct on part, cooled toolinsert recommended - 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 3.0 4.0 2.5, 3.0, 3.5 3.0, 3.5, 4.0 direct on part cooled + hardened toolinsert recommonded direct on part for amorphous materials, cooled + hardened toolinsert recommonded direct on part for semi-crystalline materials, or cold runner applications direct on part for semi-crystalline materials, or cold runner applications direct on part for semi-crystalline materials, or cold runner applications 0, 30, 0-30 MOD. 3.0 direct on part for semicrystalline materials, or cold runner applications fast cycle cosmetic gate gate vestige wear resistant PE PP PEEK PPS PET PBT PA6 PA6.6 PA4.6 PPA POM Homo POM Copo LCP PMMA ABS ASA SAN PS PPE PC PES PSU PEI SMA PVC soft PC/ABS PC/PBT PA/ABS TPE-O/S/V TPE-U Disclaimer: For resins not mentioned in the overview or specific applications please consult Synventive. Highly Suitable © Synventive Molding Solutions 2014-12-17 Suitable CAT-14-0001_EN-REV03 10 / 14 Consult Synventive Not Suitable All rights reserved. Errors and exceptions excepted. Hot Runner Guide Material suitability: Nozzle size 16 Tip shape Version Gating 16 E01 Parameters Extension (F) Gate Ø (H) Material suitability Applications thermopl. elastomers blends amorphus thermoplastics semi-crystalline thermoplastics Material S 01 T W 01 T W 10 V W 25 V ● ● ● ● ● T A Illustrations simplified, schematically drawn and not to scale. All dimensions in mm. V 10 V V 25 V S 10 V S 25 V ● ● ● ● L Related nozzle series 16 K 27 N C P 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 2.5, 2.8, 3.2, 3.6, 4.0, 4.5 2.4, 2.7, 3.0, 3.3, 3.6, 3.9 cold runner applications direct on part for semi-crystalline materials, or cold runner applications 2.4, 2.7, 3.0, 3.3, 3.6, 3.9 4.0, 4.5, 5.0 direct on part, direct on part cooled toolinsert cooled + hardrecommended ened toolinsert recommonded 4.0, 4.5, direct on part for amorphous materials, cooled + hardened toolinsert recommonded 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 5.0 4.5 5.0 direct on part for semi-crystalline materials, or cold runner applications direct on part for semi-crystalline materials, or cold runner applications direct on part for semi-crystalline materials, or cold runner applications 0, 30, 0-30 MOD. 4.5 direct on part for semicrystalline materials, or cold runner applications fast cycle cosmetic gate gate vestige wear resistant PE PP PEEK PPS PET PBT PA6 PA6.6 PA4.6 PPA POM Homo POM Copo LCP PMMA ABS ASA SAN PS PPE PC PES PSU PEI SMA PVC soft PC/ABS PC/PBT PA/ABS TPE-O/S/V TPE-U Disclaimer: For resins not mentioned in the overview or specific applications please consult Synventive. Highly Suitable © Synventive Molding Solutions 2014-12-17 Suitable CAT-14-0001_EN-REV03 11 / 14 Consult Synventive Not Suitable All rights reserved. Errors and exceptions excepted. Hot Runner Guide Material suitability: Nozzles size 22 Tip shape Version Gating 22 E01 Parameters Extension (F) Gate Ø (H) Material suitability Application thermopl. elastomers blends amorphus thermoplastics semi-crystalline thermoplastics Material S 01 T W 01 T W 10 V W 25 V ● ● ● ● ● T A Illustrations simplified, schematically drawn and not to scale. All dimensions in mm. V 10 V V 25 V S 10 V S 25 V ● ● ● ● 0, 30, 0-30 MOD. L Related nozzle series 22 K 27 N C P 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 2.8, 3.2, 3.6, 4.0, 4.5, 5.0 2.7, 3.0, 3.3, 3.6, 3.9, 4.2 cold runner applications direct on part for semi-crystalline materials, or coldrunner applications - - 2.7, 3.0, 3.3, 3.6, 3.9, 4.2 5.0, 5.5, 6.0, 7.0 direct on part, cooled toolinsert recommended direct on part cooled + hardened toolinsert recommonded - 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 0, 30, 0-30 MOD. 5.5, 6.0, 6.5 6.0 6.0 6.0 direct on part for amorphous materials, cooled + hardened toolinsert recommonded direct on part for semi-crystalline materials, or cold runner applications direct on part for semi-crystalline materials, or cold runner applications direct on part for semi-crystalline materials, or coldrunner applications 6.0 direct on part for semicrystalline materials, or coldrunner applications fast cycle cosmetic gate gate vestige wear resistant PE PP PEEK PPS PET PBT PA6 PA6.6 PA4.6 PPA POM Homo POM Copo LCP PMMA ABS ASA SAN PS PPE PC PES PSU PEI SMA PVC soft PC/ABS PC/PBT PA/ABS TPE-O/S/V TPE-U Disclaimer: For resins not mentioned in the overview or specific applications please consult Synventive. Highly Suitable © Synventive Molding Solutions 2014-12-17 Suitable CAT-14-0001_EN-REV03 12 / 14 Consult Synventive Not Suitable All rights reserved. Errors and exceptions excepted. Hot Runner Guide What is the shot weight per nozzle used for? The 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. C P T A 1 The 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 molded parts to be produced. W = W + + How to find the shot weight per nozzle (W) is shown on the right for three different applications. Several parts per nozzle Multi cavity mold with sprue bushing Gating on cold sub runner Shot weight per nozzle = Parts + runner 2 One part per nozzle Multi cavity mold with manifold system Direct gating on to the part W1 Shot weight per nozzle = part W1 = W2 = Several nozzles per part Single cavity mold with manifold system Direct gating on to the part W2 Shot weight per nozzle = Section of the cavity which is filled by one nozzle The maximum shot size that can be achieved depends on several factors: à Injection time à Type of plastic: viscosity, additives, etc. 3 à Runner length/diameter à Maximum permitted pressure loss à Residence time When the above factors are taken into consideration, conflicting requirements may arise in some cases. W1 Flow channel as big as possible: W2 à Iow pressure loss à low shear rate W1 = W2 = W3 = Flow channel as small as possible: W3 à Iow residence time à good melt exchange The values for the maximum shot weight of Synventive nozzle have been derived from practical experience as well as theoretical studies. They are valid for non filled materials.For a specific application, please always consult Synventive. © Synventive Molding Solutions 2014-12-17 CAT-14-0001_EN-REV03 13 / 14 All rights reserved. Errors and exceptions excepted. Hot Runner Guide Thermal expansion guidelines Ratio of pitch dimension to nozzle length for threaded nozzles X = 300 mm L = min. 100 mm Nozzle type = 12E X = 650 mm L = min. 200 mm 300 Very Suitable 250 Minimum allowable L (mm) Nozzle type = 06E T A 06E The thermal expansion of the manifold makes the nozzle move while the nozzle tip is fixed inside the mold cut out. In order to allow the nozzle to bend without being damaged the nozzle must adhere to a minimum length. These graphs show the minimum length of a threaded nozzle in relation to its pitch dimension. Example: C P 200 150 100 Consult Synventive Molding Solutions 50 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 Radial Distance X (mm) 09E 12E 300 300 Very Suitable Very Suitable 250 Minimum allowable L (mm) Minimum allowable L (mm) 250 200 150 100 200 150 100 Consult Synventive Molding Solutions 50 Consult Synventive Molding Solutions 50 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 Radial Distance X (mm) Radial Distance X (mm) 16E 22E 300 300 Very Suitable Very Suitable 250 Minimum allowable L (mm) Minimum allowable L (mm) 250 200 150 100 200 150 100 Consult Synventive Molding Solutions 50 Consult Synventive Molding Solutions 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 50 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 Radial Distance X (mm) © Synventive Molding Solutions 2014-12-17 Radial Distance X (mm) CAT-14-0001_EN-REV03 14 / 14 All rights reserved. Errors and exceptions excepted. Contents Layout and Design 2 The indivdual Hot Runner solution from modular components 3 Overview of Nozzle Series 4 Key Data of Hot Runner Nozzles 5 Manifolds6 Actuators7 Material suitability: Nozzles, size 03, 04 8 Material suitability: Nozzles, size 06 9 Material suitability: Nozzles, size 09 10 Material suitability: Nozzle series 12E 11 Material suitability: Valve gate nozzles, size 12 12 Material suitability: Open nozzles, size 16 13 Material suitability: Valve gate nozzles, size 16 14 Material suitability: Open nozzles, size 22 15 Material suitability: Valve gate nozzles, size 22 16 Designing the interface between cavity and runner North America 17 Designing flow channel and interface to machine nozzle DefiningInc. the cavity gate diameter Synventive Molding Solutions 10 Centennial Drive What is the shot weight per nozzle used for? Peabody, MA 01960 Thermal expansion guidelines Tel.: +1 978 750 8065 Thermal expansion guidelines Fax: +1 978 646 3600 Email: info@synventive.com Europe Synventive Molding Solutions GmbH Heimrodstraße 10 P. O. Box 3123 64625 Bensheim Tel. :+49 (0)6251 9332-0 Fax :+49 (0)6251 9332-90 Email: infohrde@synventive.com Asia Synventive Molding Solutions (Suzhou) Co. Ltd. 12B Gang Tian Industrial Square Suzhou Industrial Park, China 215021 Tel.: +86 512 6283 8870 Fax: +86 512 6283 8890 Email: infohrcn@synventive.com CAT-14-0001_EN-REV03 2014-12-17 ©2014 Synventive Molding Solutions DTP: KA 18 19 20 21 22
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