Hot runner system eliminates waste, increases productivity

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Using flat nozzles minimises space requirements

The sealing ring is produced in a one-drop mould. The tool had to be constructed in a way that would minimise the size of the required injection moulding machine for the production of the parts. Since the projection space of the ring is relatively small, only a slight uplift pressure is yielded. Slide dampers were used in order to solve the problems resulting from the undercuts in the plastic part.

A great advantage for the mould design is the small installation space required by the flat shape of the Star-Line nozzles. In other applications, this advantage can be used for the side gating of plastic parts with only one injection point. Furthermore, the Star-Line nozzles with their various types that can be used with one up to eight tips for side gating offer a lot of possibilities to the technical product designer and the mould designer, which other nozzles simply cannot.

The length of the nozzles, the location of the injection point and the position inside the tool are almost unlimited and that is why Heitec calls it Freedimensional. So the mould designer is finally able to inject the plastic part exactly at the desired point and not only where the mould allows it.

In case of the sealing ring, the nozzles of the type 01.076.44.01.L were arranged in a star-like pattern that is reminiscent of star engines from ancient airplanes. Another major advantage of the hot runner system is that the length expansion, especially in the case of very long nozzles, is no longer a problem, because the length expansion is completely compensated for within the system. Therefore, no such problems like moving injection points and elongated holes arise.

Another great advantage of the nozzles, in comparison to similar products, is the very precise thermal profile, which enables the customer to process even challenging materials, including those for technical plastics, high temperature materials or filled materials. For this reason, it was no problem to process the Polyamide filled with 35% glass fibre.

Nozzle arrangement suitable for a range of applications

The principle of the arrangement of the nozzles can, of course, not only be used for the production of rings and similar applications, but can also be helpful to realise applications like, for example, the inside injection of cans, pots, boxes and body housings. The sealing ring could have also been injected from the outside with the use of six nozzles, if the plastic part had required this.

In summary, the customer was able to considerably reduce his material demand by approximately 66%, which helped to lower the costs of production. Furthermore, additional duties like the collection and extra handling of the sprue are eliminated. Not to mention the fact that saving material is quite a win for our environment. Weha complimented the design solution developed by Heitec using the Star-Line nozzles and the great advantages concerning the production process and the increased productivity. Besides that, Weha is quite impressed by the accuracy of the plastic part, which is absolutely necessary to guarantee the functionality of the sealing ring.

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