hot runner technology dynamic feed flowcontrol

In 26 countriesworldwide

www.synventive.com

North America

Synventive Molding Solutions Inc.10 Centennial DrivePeabody, MA 01960, USATel.: +1 978 750 8065Fax: +1 978 646 3600E-Mail: [email protected]

H O T R U N N E R T E C H N O L O G Y H O T R U N N E R T E C H N O L O G Y

FlowControlStabilize your Process

FlowControlSmart & Effective

Stabilize your Process

Europe

Synventive Molding Solutions GmbHHeimrodstr. 1064625 Bensheim, GermanyTel.: +49 (0)6251/9332-0Fax: +49 (0) 6251/ 9332-90E-Mail: [email protected]

Asia

Synventive Molding Solutions (Suzhou) Co.Ltd.12B Gang Tian Industrial SquareSuzhou Industrial Park, China 215021Tel.: +86 512 6283 8870Fax: +86 512 6283 8890E-Mail: [email protected]

KNOWLEDGE &CONSULTANCY

STABILIZEYOUR

PROCESS

LEADINGTECHNOLOGIES

GLOBALSERVICES

CUSTOMSOLUTIONS

Dynamic Feed®

Ultimate ControlIndividual melt pressure control at each gate

Dynamic Feed® provides individual melt pressure control in each gating area. Every gate receives the precise injection and pack pressure profile that is predefined for their position, giving you the same level of control as having separate injection units located at each hot runner nozzle. In the injection and pack pressure stages, the filling of the cavity is individually adjusted and controlled by intelligent software.

Differences in flow velocity, differential pressure in the cavity, or influences of deviating material visco-sities during the filling are eliminated by Dynamic Feed. Additionally, sink marks and dimensional stability are greatly improved by the custom pack pressure profile. As a result, dimensional stable parts with the highest level of surface quality can be manufactured in a way that is both process sta-ble and reproducible.

Dynamic Feed assures the highest qualities with excellent surfaces, including tightest tolerances, dimensional stability and perfect reproducibility of complex molded parts.

Dynamic Feed®For a wide variety of injection molding applications:

in single cavity molds: for complex part geometries in multi cavity molds: for precision and consistency

in higher cavitation molds in modular molds: for different cavities in the mold

base and modular tool inserts in family molds: for different or complementary

parts in one mold unit

H O T R U N N E R T E C H N O L O G Y


Dyn

amic

Fee

d®

TargetActual

FlowControl-P200USzrev2.indd 1 3/1/2012 4:47:51 PM

Nozzle 1 Cycle: 3316 Nozzle 2 Cycle: 3316

Cycle Time (sec) Cycle Time (sec)

01

-2

-4

-6

-8

-10

-12

Pin

Pos

ition

(mm

)

01

-2

-4

-6

-8

-10

-12

Velocity (mm

/sec) Pin

Pos

ition

(mm

) Velocity (mm

/sec)

-50-40-30-20-1001020304050

-50-40-30-20-1001020304050

0 0.5 1 1.5 1.6 0 0.5 1 1.5 1.6

Valve opening control for hydraulic valve gate systems in cascade molding

SynFlow® is a velocity and position-dependent opening stroke control system for hydraulic valve gated hot runner systems. It allows the user to de-fine the opening velocity of the valve pin and the amount of the opening stroke over which the velo-city will be controlled.

the designated opening velocity

the length of the opening stroke which the

opening velocity is controlled (at the end of the

defined opening stroke the velcity will raise back

to maximum.)

By regulating the flow of hydraulic fluid to the opening port of the valve gate piston, SynFlow® is able to control how quickly the valve pin opens. Users gain a level of control that allows for a regulated release of melt pressure into the cavity



SynFlow®

Optimized flow control eGate®

Surface quality & dimensional stability Stable processes through advanced flow control

Until now, the filling process in multiple gated parts has only been controlled by the opening and closing of the valve gates. The molder can choose when the pins open and close but he has no control over the speed and stroke of the valve pins. This can make it difficult to achieve premium quality parts, especially when cascade molding with difficult cosmetic requirements.

In cascade molding the filling of the part begins out of one or more gates while the other gates remain closed until the flow front passes them. This is done to eliminate weld lines but can cause other types of cosmetic defects. While the flow front is advancing in the part out of the originally opened gates, pressure is building inside the hot runner behind the gates that are still closed. When these gates finally do open the highly pressurized plastic inside the hot runner is released into the cavity causing a sudden acceleration of the flow front near the newly opened gate. This sudden release of pressure also causes a pressure decline at the originally opened gates, resulting in a temporary deceleration of the flow front in other areas of the part. These abrupt flow front velocity changes, and therefore the flow marks resulting from them, can be greatly reduced or eliminated by individually controlling the velocity and stroke of each valve pin.

SynFlow®, eGate® and Dynamic Feed® are Synventive technologies which provide flow control to produce parts with perfect surface quality, dimensional stability and reproducibility.

Demanding visual appearance with precise dimensional stability

Gloss level, evenly textured surfaces, color uniformity and aesthetics, are all determinants for the visual quality of modern plastic parts. In addition to these factors, today’s parts also require optimum dimensional stability and perfect surfaces in the gating area. Molding quality parts is more challenging than ever, and common molding processes often are not sufficiently meeting these requirements. Complete control of the plastic flow is necessary to reduce or eliminate defects and ensure high quality, consistent molded parts.

Electronically controlled valve gate system provides cleanliness, energy efficiency, precision and flow control

eGate® is an electronically controlled valve gate system which provides significant advantages over conventional hydraulic and pneumatic actuation beyond the obvious cleanliness and energy efficiency. With response times of less than .001 seconds and precise position control to .01mm, eGate offers unparalleled repeatability. Through its ability to adjust the valve pin’s open position, close position, velocity and acceleration, eGate provides advanced flow control for the most demanding cosmetic applications.

Examples of premium consumer and electronic products producible with eGate systems

Differing valve pin velocities at each cycle

Sink marks after coating Two examples of advanced surface qualities by using SynFlow


Flow marks Opposite gating marks

Real-time process monitoring of pin position and velocity

Response times of less than .001 sec

Open and close position repeatability to .01 mm

Ability to adjust and control the pin’s open

position, close position, velocity and acceleration

No plumbing or gun-drilling of hydraulic or

pneumatic lines

Ideal for “all-electric” molding and clean room

applications

eGate® offers cost-effective, high quality and process stable manufacturing to its users. With eGate the best qualities for sensitive part surfaces can be obtained, resulting in excellent aesthetics.

selective reduction of the valve pin opening velocity where it’s most effective

real-time valve-pin position monitoring

reproducible velocity regulation

precise control of the opening profile

prevents molding defects such as:

pressure alteration marks

opposite direct gating marks

sink marks

reduced adhesion of finishes

The user gets clean parts with perfect surface quality, reducing rejects and improving process efficiency.

eGate® benefits:

With SynFlow® you can define:

SynFlow® benefits:

eGat

e®

SynF

low

®

Flow front accelerations and stagnations can cause visible surface defects.

Fill time_1= 8.926 [s]

8.926

7.508

6.089

4.671

3.252

[s]

Filling details:

Typical error patterns:

The opening of the outer nozzles causes a localized spike in pressure as well as a corresponding pressure decline away from the gate.

Bumper-Seq Pressure at gates

Nozzle group 3 open

Nozzle group 4 open

MP

a

80.00

70.00

60.00

50.00

40.00

30.00

20.00

10.00

0.0000

0.0000 2.250 4.500 6.750 9.000

Opening with defined velocity profile

Valve pin opened

TIME

Valve pin closed0mm

4mm

20mm

Sec.



www.synventive.com

North America






Europe


Asia



STABILIZEYOUR

PROCESS

LEADINGTECHNOLOGIES

GLOBALSERVICES

CUSTOMSOLUTIONS

Dynamic Feed®












Dyn

amic

Fee

d®

TargetActual


Nozzle 1 Cycle: 3316 Nozzle 2 Cycle: 3316

Cycle Time (sec) Cycle Time (sec)

01

-2

-4

-6

-8

-10

-12

Pin

Pos

ition

(mm

)

01

-2

-4

-6

-8

-10

-12

Velocity (mm

/sec) Pin

Pos

ition

(mm

) Velocity (mm

/sec)

-50-40-30-20-1001020304050

-50-40-30-20-1001020304050

0 0.5 1 1.5 1.6 0 0.5 1 1.5 1.6

Valve opening control for hydraulic valve gate systems in cascade molding

SynFlow® is a velocity and position-dependent opening stroke control system for hydraulic valve gated hot runner systems. It allows the user to de-fine the opening velocity of the valve pin and the amount of the opening stroke over which the velo-city will be controlled.

the designated opening velocity

the length of the opening stroke which the

opening velocity is controlled (at the end of the

defined opening stroke the velcity will raise back

to maximum.)

By regulating the flow of hydraulic fluid to the opening port of the valve gate piston, SynFlow® is able to control how quickly the valve pin opens. Users gain a level of control that allows for a regulated release of melt pressure into the cavity



SynFlow®

Optimized flow control eGate®

Surface quality & dimensional stability Stable processes through advanced flow control

Until now, the filling process in multiple gated parts has only been controlled by the opening and closing of the valve gates. The molder can choose when the pins open and close but he has no control over the speed and stroke of the valve pins. This can make it difficult to achieve premium quality parts, especially when cascade molding with difficult cosmetic requirements.

In cascade molding the filling of the part begins out of one or more gates while the other gates remain closed until the flow front passes them. This is done to eliminate weld lines but can cause other types of cosmetic defects. While the flow front is advancing in the part out of the originally opened gates, pressure is building inside the hot runner behind the gates that are still closed. When these gates finally do open the highly pressurized plastic inside the hot runner is released into the cavity causing a sudden acceleration of the flow front near the newly opened gate. This sudden release of pressure also causes a pressure decline at the originally opened gates, resulting in a temporary deceleration of the flow front in other areas of the part. These abrupt flow front velocity changes, and therefore the flow marks resulting from them, can be greatly reduced or eliminated by individually controlling the velocity and stroke of each valve pin.

SynFlow®, eGate® and Dynamic Feed® are Synventive technologies which provide flow control to produce parts with perfect surface quality, dimensional stability and reproducibility.

Demanding visual appearance with precise dimensional stability

Gloss level, evenly textured surfaces, color uniformity and aesthetics, are all determinants for the visual quality of modern plastic parts. In addition to these factors, today’s parts also require optimum dimensional stability and perfect surfaces in the gating area. Molding quality parts is more challenging than ever, and common molding processes often are not sufficiently meeting these requirements. Complete control of the plastic flow is necessary to reduce or eliminate defects and ensure high quality, consistent molded parts.

Electronically controlled valve gate system provides cleanliness, energy efficiency, precision and flow control

eGate® is an electronically controlled valve gate system which provides significant advantages over conventional hydraulic and pneumatic actuation beyond the obvious cleanliness and energy efficiency. With response times of less than .001 seconds and precise position control to .01mm, eGate offers unparalleled repeatability. Through its ability to adjust the valve pin’s open position, close position, velocity and acceleration, eGate provides advanced flow control for the most demanding cosmetic applications.

Examples of premium consumer and electronic products producible with eGate systems

Differing valve pin velocities at each cycle

Sink marks after coating Two examples of advanced surface qualities by using SynFlow


Flow marks Opposite gating marks

Real-time process monitoring of pin position and velocity

Response times of less than .001 sec

Open and close position repeatability to .01 mm

Ability to adjust and control the pin’s open

position, close position, velocity and acceleration

No plumbing or gun-drilling of hydraulic or

pneumatic lines

Ideal for “all-electric” molding and clean room

applications

eGate® offers cost-effective, high quality and process stable manufacturing to its users. With eGate the best qualities for sensitive part surfaces can be obtained, resulting in excellent aesthetics.

selective reduction of the valve pin opening velocity where it’s most effective

real-time valve-pin position monitoring

reproducible velocity regulation

precise control of the opening profile

prevents molding defects such as:

pressure alteration marks

opposite direct gating marks

sink marks

reduced adhesion of finishes

The user gets clean parts with perfect surface quality, reducing rejects and improving process efficiency.

eGate® benefits:

With SynFlow® you can define:

SynFlow® benefits:

eGat

e®

SynF

low

®

Flow front accelerations and stagnations can cause visible surface defects.

Fill time_1= 8.926 [s]

8.926

7.508

6.089

4.671

3.252

[s]

Filling details:

Typical error patterns:

The opening of the outer nozzles causes a localized spike in pressure as well as a corresponding pressure decline away from the gate.

Bumper-Seq Pressure at gates

Nozzle group 3 open

Nozzle group 4 open

MP

a

80.00

70.00

60.00

50.00

40.00

30.00

20.00

10.00

0.0000

0.0000 2.250 4.500 6.750 9.000

Opening with defined velocity profile

Valve pin opened

TIME

Valve pin closed0mm

4mm

20mm

Sec.



www.synventive.com

North America






Europe


Asia



STABILIZEYOUR

PROCESS

LEADINGTECHNOLOGIES

GLOBALSERVICES

CUSTOMSOLUTIONS

Dynamic Feed®












Dyn

amic

Fee

d®

TargetActual


hot runner technology dynamic feed flowcontrol

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