Page 1
Hot Runners
Performance, application flexibility and reliability
FROM CONFIGURABLE PRONTO SYSTEMS TO CHALLENGING CUSTOM STACK AND MULTI-MATERIAL SYSTEMS,
HUSKY HAS A SOLUTION FOR YOUR APPLICATION.
Our commitment to development has led to new technologies that help reduce our customers’ operating costs.
UltraFlow melt mixing homogenizes the melt, improving
part quality and color change time. And new advances in
nozzle tip design and materials provide wider operating
windows and longer service life.
Two dedicated hot runner manufacturing facilities, in
Dudelange, Luxembourg and Vermont, U.S.A., provide competitive lead times to our global customers. Our service and
sales network, serving over 100 countries with dedicated
Husky personnel, ensures consistent support during mold
design, build, start-up and operation.
Page 2
PRODUCTS
OUR HOT RUNNERS ARE AVAILABLE AS COMPLETE HOT HALVES OR AS MANIFOLD SYSTEMS. WE OFFER SINGLE–SOURCE
RESPONSIBILITY TO SIMPLIFY COMMUNICATION AND ENSURE RELIABLE OPERATION.
COMPLETE HOT RUNNER SYSTEMS
Every hot runner we build is optimized for its
specific application. Our systems include:
• High cavitation systems (up to 144-drop valve gates)
• Stack systems up to 2 x 96 drops
• Multi-material systems
• Sequentially valve gated systems
• Non-symmetrical and family mold hot runners
• Pronto standard systems for fast delivery and
reduced cost
• Three-year leakproof guarantee
• Full testing prior to shipment
Every hot runner we build is optimized by
selecting from a wide range of standard
components and configurations.
2
Hot Runners
Page 3
MOLD BASES
Our custom mold bases improve output and extend mold life.
Mold base technologies include:
• Rotating Ratchet Ring (RRR) for improved cycle times and reduced
maintenance on unscrewing applications
• SwingChutes for reliable part removal
• Stack mold bases which nearly double the output per machine
TEMPERATURE CONTROLLERS
Our temperature controllers deliver precise temperature control
for low and high cavitation hot runners. Features include:
• Consistent part quality with PID2 control
• Extended heater life with voltage proportioning
• Easy-to-use operator interface
• System diagnostics with Mold Doctor software
MANIFOLD SYSTEMS
Manifold systems offer the flexibility of integrating key components
into your mold design.
Manifold systems include:
• Manifold design optimized for its specific application
• Fully assembled and finished manifold
• Ultra nozzle assemblies
• Electrical components
• Design guidelines and drawings that allow for
easy installation at the moldmaker’s facility
Keeping our customers in the lead 3
Page 4
THE ULTRA ADVANTAGE
OVER FIVE MILLION CYCLES
The UltraGuide nozzle tip utilizes a composite of a thermally conductive, and a
tough wear-resistant material.
• The thermally conductive material provides easy start-up and a wide
operating window when processing olefins or engineering grade resins
• The wear-resistant component of the tip has run over five million cycles
without wear on the valve stem or gate
• A wear-resistant tip insert is also available for abrasive materials using hot tips
Advanced metallurgy combined with precise
guidance delivers high wear resistance.
WIDER OPERATING WINDOW
The thermal design of the Ultra nozzle and tip provides up to three times the
temperature operating window compared to conventional designs. This wider
operating window can provide:
• No stringing or freeze-off over a wide temperature range
• Faster cycle times
• Reduced heat load
Ultra tip provides up to three times larger
temperature operating window.
4
Hot Runners
Every component of a Husky hot runner is thermally
and mechanically optimized to assure reliable operation. Valve gate stack shown on top and thermal tip
stack shown below.
Page 5
SIMPLIFIED OPERATION DELIVERS IMPROVED RELIABILITY
Ultra nozzles make valve gating simple. Key features of the Ultra valve gate’s actuation are:
• A single o-ring operating in the cooled backing plate more than doubles seal life and
maintenance interval
• Ability to valve gate higher temperature materials such as PEEK and Polysulfone (PSU)
• Large airflow access holes allow for fast valve stem actuation times providing better part
quality and consistency
• Valve stems are easily replaceable in the machine
A single o-ring operates in a cooled backing plate,
extending seal life and maintenance intervals.
GUARANTEED LEAKPROOF
All Ultra
nozzles feature the UltraSeal spring to preload the nozzle to the manifold.
UltraSeal prevents leakage at start-up, even if the hot runner is not at proper operating
temperature. We guarantee it for three years on complete sytems. UltraSeal also:
• Protects the system from damage caused by overheating
• Assures reliable operation within an operating window of up to ±100 C° (±180 F°)
The UltraSeal spring preloads the nozzle
against the manifold, making it leakproof.
Keeping our customers in the lead 5
Page 6
6
Hot Runners
Page 7
SYSTEM DESIGN
OUR HOT RUNNER SYSTEMS ARE DESIGNED WITH FACTORY OPERATING COSTS IN MIND. OUR DESIGN PRINCIPLES FOCUS
ON PART-TO-PART CONSISTENCY, REDUCED MOLD MAINTENANCE, AND UPTIME.
OPTIMIZED AND BALANCED MELT CHANNELS
Every Husky hot runner undergoes melt flow analysis to confirm equal
pressure distribution to each drop. Shear rate, residence time, and system
pressure drop ensure balanced part filling and reduce the risk of material
damage. Manifolds with more than four drops feature level changes
for improved balance. Tests have shown that introducing level changes
can improve balance by more than 10%. This means better part-to-part
consistency.
THERMAL LAYOUT
Our manifold heater layouts follow rigid design guidelines based on thermal
FEA analysis to ensure thermal balance. Heat loss is reduced by minimizing
the contact of thermally conductive materials with the plates. The manifold
and backing plate are cooled to reduce potential mold wear caused by
perature variances.
tem-
MINIMIZED PLATE DEFLECTION
Husky’s designers use guidelines that were developed using FEA models to
minimize plate and mold deflection, reducing mold wear. Integrated pillars
and contoured pockets reduce the potential for plate deflection. Studies have
proven that a contoured pocket design provides up to four times less deflec
tion than open pocket designs.
IN-MACHINE MAINTENANCE
The simplicity of our system design allows in
components: nozzle tips, heaters, valve stems, and o-rings.
-machine maintenance for key
-
Maintenance can be completed in 20% of the time required on
the workbench.
Keeping our customers in the lead 7
Page 8
ULTRA SOLUTIONS
MEDICAL DEVICE
Critical gate quality, on every part
A medical molder needed excellent gate quality to prevent
puncturing gloves while handling an umbilical cord cutter.
And they needed it fast.
Solution: A Pronto 4-drop valve-gated hot runner was
delivered in four weeks, consistently providing gates with
no standing vestige.
TAMPER-EVIDENT BEVERAGE CLOSURE
Cavity-to-cavity balance
A high-output closure system needed excellent gates and
cavity-to-cavity balance with no stringing.
Solution: A 2 x 64-drop Ultra 500 HT stack system produces
1 100 parts per minute in a 24/7 operation, to the exacting
standards of the food industry.
AUTOMOTIVE GRILL
Structural integrity and no flow-lines
Our customer needed a system for molding a 1.6 kg (3.5 lb)
automotive component with the ability to control resin flow
during fill.
Solution: A 15-drop Ultra 1000 VX hot runner with sequential gating allows the cavity to be filled with each valve gate
individually controlled.
www.husky.ca
www.hotrunners.com
Americas
288 North Road
Milton, Vermont
USA 05468
Toll Free (800) 516 9590
Tel. (802) 859 8000
Fax (802) 859 8322
Europe
Zone Industrielle Riedgen
Technical Center, B.P. 93
L-3401 Dudelange
Luxembourg
Tel. (352) 52 11 51
Fax (352) 52 11 5 4458
Recycled paper, containing a minimum of 20% post consumer fiber.
®/© 2004 Husky Injection Molding Systems Ltd.
Printed in Canada. October 2004
Loading...