HRS flow presents a new family mould for one-shot production of three high-quality visible parts for a door module for car interiors. The use of the Flexflow technology ensures finely grained surfaces without pressure lines or flow marks.
Flexflow manages the individual control of the servo-electric drives for all the eight hot runner valve gate systems used in this application.
The mould, equipped with hot runner nozzles from HRS flow's middle range, is designed for sequential injection moulding. The aligned opening of these nozzles, which is made possible by Flexflow, alleviates the pressure loss that often occurs during this injection moulding process, and thus eliminates the accompanying surface marks. And, thanks to the ability to precisely control the pressure on each nozzle during the holding pressure phase, the exact shrinkage of the desired part can be attained in each individual cavity. In regard to the cross-sections, the overall hot runner system is also designed so material and colour changes can be performed quickly.
The mould, which is intended primarily for processing propylene and additionally ABS, will be available to HRS flow customers for trials with their own materials. Stephan Berz, Vice President of HRS flow: "Having last year presented a well-balanced hot runner solution for the production of high-quality, chrome-platable radiator grille elements in a single shot, we now also have a corresponding, high-performance solution for the vehicle interior. The control of the mould-filling process using the Flexflow technology is able to satisfy particularly demanding specifications. The volumes of the three elements in the new demonstrator mould – door liner, map pocket and reinforcing bar – are 560 cm³, 338 cm³ and 58 cm³ respectively, while the average wall thickness varies between 2.3 mm with the largest part and 3 mm with the smallest one. The fine grain of the visible surfaces and the delicate open net structure of the loudspeaker grille integrated into the map pocket are real challenges that we have successfully mastered."
Also available in smaller size
As an alternative to the full Flexflow technology, operators can also utilize the Flexflow One product, in which a responsive driver module coupled to each individual nozzle controls the melt flow. The processor transmits the individual data on valve pin position, stroke and velocity to the respective module, which then automatically controls the valve pin motion.
Berz continued: "Our new family mould for vehicle interior parts is designed for an injection moulding machine with a clamping force of 10,000 kN. In order to be able to gain information about the mould-filling process, we have placed two pressure sensors in each of the two larger cavities and one in the small one. In addition, six contact sensors provide information about the mould deflection during the injection phase. This configuration gives our customers the possibility to see for themselves and with their own material the quality and efficiency benefits that this system offers in production. If desired, HRS flow will then provide support with transferring the combination of family mould and Flexflow technology to the respective customer-specific application."