Hot Runner Solutions and Control Systems

Transcription

1 Hot Runner Solutions and Control Systems

2 Canada USA Brazil Germany Global hot runner solutions Providing leading technical solutions, lowering total overall costs, and minimizing business risk to our clients, from the global leader of melt delivery and control systems. Always thinking, always ready, always there

3 UK France Austria China Japan India Singapore Korea Manufacturing Facilities technologically engineered to drive down part costs Run faster cycle times, reduce part scrap, achieve best in class color change times combined with the most reliable and energy efficient heating system. These advancements are why Mold-Masters focuses on and invests so much in innovative technology. a solution for every challenge Our team of solution centric application experts have unequaled experience and knowledge in the most demanding applications. We combine technologies like FEA and simulation techniques with real life experience to excel for our clients. global manufacturing footprint and capacity With six major production facilities on four continents and MasterCARE service centers globally, no company can support global tooling and molding customers like Mold-Masters. Speed to market, global capacity, and local market support... unparalelled. innovation With over 900 patents, Mold-Masters continues to be the innovation leader in the injection molding industry. Through our dedicated R&D center, the continuous search for new ways to deliver added value has led to the creation of innovative products such as Accu-Valve, Melt-CUBE, Fusion G2, E-Multi and our advanced MPET platform. service and support you can count on We support you for the entire lifecycle of your mold with our global MasterCARE teams and innovative services such as STAMP, Merlin and MasterSPEED. Our knowledgeable and passionate people are committed to providing the best customer care experience in the industry. Plus we offer the best warranty in the industry. Serving All Key Markets Automotive Caps/Closures Electronics Housewares Medical Packaging Personal Care Technical

4 The benchmark in hot runner performance Every Master-Series system is engineered to provide better part quality and faster cycle times. With over 1,500,000 nozzles in the field, Master-Series technology has set the benchmark in hot runner performance and reliability. most reliable Mold-Masters has created the industry s most thermally precise and reliable nozzle platform using proprietary in-house heating elements, patented multi-material tip geometries and unique heater brazing technology. Master-Series nozzles are backed by a comprehensive warranty program that is 3 to 5 times longer than any other supplier. more versatile Master-Series nozzles come in six standard sizes, in lengths from 27mm to 440mm and in more than 20 standard gate configurations including hot tip, valve gate, sprue gate and edge gate. No other nozzle platform provides the flexibility to put the gate in difficult to mold locations while offering the best steel and cooling conditions. fastest Color Changes The industry s fastest color changes are achieved via an optimized thermal profile and patented nozzle tip geometry. The proprietary iflow manifolds reduce sheer heat generation, lower energy consumption, improve balance and reduce pressure drop, all resulting in better color changes. Proven line of gating solutions

5 and reliability Hot Tip Gating 3 4 Uniform heating for optimal gate CONTROL The brazed heater (1) delivers uniform heat from flange to gate, uses 20% less power, never shifts and lasts the life of the tool. Using a patented combination of materials in the gate seal area (2), Master-Series creates optimal thermal conditions for the resin while ensuring mechanical integrity. Robust and Durable Nozzles and tips Master-Series nozzles withstand up to 3,000 bar (44,000 psi) injection pressures. The flange (3) is designed to reduce heat loss from the back of the nozzle while providing a robust seal-off. A sealed terminal end (4) prevents degradation and corrosion of the heater wiring. The innovative Visco-Seal (5) creates secondary leakage protection between the gate seal and cavity. Removeable and robust tips and gate seals (6) machined from innovative materials make in-press service quick and easy. Optional tips and seals are available for aggressive and corrosive resins. 1 Brazed in heaters provide uniform and consistent heating 6 5 2

6 The new standard for valve gate performance The Accu-Valve cylindrical valve gating system is the most reliable valve gate system, using a patented design with precise alignment, optimal gate temperature control and robust valve actuation. CX FOR COMMODITY RESINS and fast colour change MX FOR both ENGINEERING and commodity RESIN APPLICATIONS Leading technology for part quality and longevity

7 3 THE SCIENCE OF CYLINDRICAL VALVE GATING 1 Precision Guidance of the Pin The patented V-Guide (1) system guides the pin through the manifold area. The innovative guiding mechanism in the tip (2), which requires no disengagement or direct reliance on cavity steel for pin alignment, maximizes pin and cavity life and optimizes gate quality. Maximized Reliability The V-Guide (1) creates a thermal gradient between the manifold and the back plate (3) to form a gasket-like seal at the cold end of the guide. This prevents material or gases from leaking or weeping, a common problem with conventional systems. Balanced Thermal Profile In the gate area (2), the valve pin is constantly engaged with the liner (4) to continuously conduct heat to the valve pin, improve gate cosmetics and ensure there is no resistance to pin closing. Optimized for Fast Color Change Accu-Valve CX liners use flow leaders in the liner to eliminate any stagnant flow areas in the tip. This washing action and absence of pin guides substantially enhances color change performance. CX tip showing flow leaders Accu-Valve MX is suitable for both commodity and engineering grade resins (PP, ABS, PC, POM, etc.) Its robust double valve pin guidance maintains exact alignment between the pin and cavity which ensures long lasting gate quality. 4 2

8 Industry leader in fill balance Mold-Masters unique manifold technologies enable best-in-class filling balance for critical small part or thin wall molding in high-cavity applications. The engineering principle behind the manifold design creates better internal support, resulting in longer lasting molds with less plate deflection. conventional Gun-Drilled Manifolds Gun-drilled manifolds are used when the most direct path to the gates is a straight line. The gun-drilled channels are sealed using welded-in plugs to prevent any chance of material leakage. iflow manifold technology Mold-Masters iflow manifolds are an ideal solution for applications requiring balanced fill, fast color changes and complex cavity layouts. Milling the melt channel paths into individual pieces allows for endless melt channel layout possibilities and eliminates the need for manifold plugs. The smooth and gentle corners reduce pressure drop in the manifold by more than 10%, help flush colors through the melt channels and provide exceptional fill balance. iflow vs Gun Drilled Channels on Color Change Performance uniform Heating Every manifold is analyzed to ensure that the heating is uniform over its entire surface. This aids fill balance and prevents any degradation of the material. Brazed-in heaters provide energy-efficient and long-lasting heater performance. Uniform shear generation in iflow manifolds Impact of iflow Channels vs. Gun Drilled Channels on Color Change Performance 7% Faster Time (Minutes) 15% Faster PP HDPP Gun Drilled Channel iflow Channel The most balanced hot runners in the industry

9 Fast, smooth and reliable Fast, simultaneous or sequential actuation is imperative to high quality valve gating. Mold-Masters offers pneumatic, hydraulic and electric actuation options that set the standard for valve gating. Pneumatic or Hydraulic actuation The piston is housed in the cooled back plate with access ports (1) for individual pin removal. Since the piston is not subjected to any heat, the o-rings do not need to be maintained. For tapered shut-off applications, the piston can be equipped with a spring so that the force that the piston exerts on the gate is controlled. Synchro- plate and e-drive actuation Synchro-Plate solutions are available when the pitch between cavities is too tight to use individual pistons. Synchro- Plates are available with pneumatic, hydraulic and electric actuation. The E-Drive servo driven synchro solution provides the power, cleanliness and precision of a servo motor all in a compact, energy-efficient footprint. Standard Piston Assembly E-Drive 1

10 Superior direct side gating made simple Mold-Masters innovative Melt-Disk and Melt-CUBE technologies provides precise cavity-to-cavity balance, excellent vestige control, easy start-ups and low injection pressures for a variety of crystalline and amorphous side gating applications. The Melt-CUBE and Melt-Disk products are perfect for deep draw parts such as pipettes, syringe barrels, needle shields or smaller parts where only side gating is permitted. The Melt-CUBE allows for higher pitch density compared to other designs and easy tip replacement in the press. The patent pending design also enables faster cycles and pristine gates with an additional temperature control zone at the gate. The minimized gate to parting-line distance offers an optimal thermal condition. The design offers simultaneous gating of 2 to 16 cavities and is able to process engineering grade resins. The Melt-CUBE has tips angled at 15, 30, 45 and 60 degree from horizontal. The Melt-Disk, geared towards circular orientated mold layouts, offers simultaneous side gating and is available for 2, 4, 6, or 8 parts per drop in four sizes, with tips angled at 15, 30, 45 and 60 from horizontal. MD85 MD60 Melt-CUBE MD40 Performance from Polypropylenes to Polycarbonates

11 Key features: Symmetrical geometry of the Melt-Disk and Melt-CUBE ensures complete rheological balance. Dedicated heating system (1) in the disk or cube to provide optimal heat control in the gate area. Patented sliding expansion joint (2), called the Melt-Link, between the nozzle and the Melt-Disk or the Melt-CUBE, prevents the thermal expansion of the nozzle from affecting the fixed and precise location of the tip in the gate (3). Optional individual shut-offs to each cavity (4). Melt-Start temperature controller software to automatically implement the correct start-up and shut-down sequence on all components of the system. Example of 45 degree Melt-Disk option MD85 showing individual gate shut-offs Example of 60 degree Melt-Disk option Melt-CUBE

12 Drop-in, Connect, Go The Fusion Series G2 is geared for large to medium parts, perfect for the automotive and white good markets. The drop-in, single point connection design ensures easy installation, faster start-ups, reliable operation and user-friendly maintenance. The Drop-In Advantage Convenient single or multiple point hookups for water, hydraulics or pneumatics reduce complex layouts. Wire armor protects and routes electrical and thermocouple wires, while providing a stable mounting platform. The cavity plate machining is simplified with no counter bore machining and the thru bore gate reduces gate detail. The spacer plate is optimized with no system interface required for hot runner support. The machining requirements are strictly for clearance and plate stack-up is greatly reduced. The pre-wired and pre-assembled system reduces set-up time and connection errors allowing customers to spend more time on what matters molding good parts. A Design optimized for Field Use The variable length nozzles, from 80mm to 550mm, thread directly into the nozzle to minimize heat expansion differentials. Heaters can be replaced without unthreading to allow for easy maintenance. Plus the heaters are independently controlled and come with dual thermocouples as an option. With nozzle sizes that handle shot weights of both commodity or engineering grade resin from 50g to 3500g and tip and valve gating types to suit, the plastic part options are endless. Medium to large part molding, optimized

13 The Clear Choice For Lenses Standard components and innovative angled options make Vision the clear choice for automotive lenses and white goods molding applications. The Benefits are Clear Features that differentiate Vision allows for an endless variety of angles to be designed with optimal gate locations perfected for contoured parts. This is done by using a specially engineered step that is both cost effective and durable. Like the Fusion G2, Vision comes fully assembled, pre-wired and with quick disconnects allowing for drop-in functionality. These key benefits allow the Mold-Maker to focus on the tool build and not worry about accommodating the hot runner. Field replaceable heaters and quick release actuators ensure very user friendly maintenance. The design of Vision also allows for minimized mold plate and system interface machining, thus promoting greater tool integrity. From creative tail lights to innovative white goods, Vision can be used to successfully simplify the molding of contoured parts.

14 Engineered for speed Purpose engineered hot runner systems for ultra fast, high performance closure molding. Cost is Key SPRINT systems are optimized for high performance molding at 3-6 second cycle times. The nozzle and manifold designs work together, utilizing the advantages of high injection velocity and 10% lower pressure drops then conventional systems, resulting in lighting fast part production. The high cavitation offerings ensure you can produce the numbers of parts needed, at the rate required. Plus, proven faster color changes are achieved due to the patented iflow technology, especially critical for molders changing colors several times a day. Quality Parts Reducing scrap means increasing profits. Through iflow technology and specially designed SPRINT nozzles, balanced fill and precise gate vestige is always achieved. High quality parts are produced with no stringing and low gate vestige, even at high cycle times. Brazed heaters ensure temperature consistency and cavity to cavity uniformity throughout the system.»» 64 Cavity Sprint E-Drive Valve Gate System engineered for CSD closure applications Lifecycle Cost Savings Minimal wear, ease-of-maintenance and energy savings are all major benefits of the SPRINT system. Robust nozzle tips and seals have been designed to offer minimal tip wear, plus the long-life nozzles and manifolds come with our industry best warranty. This ensures maximum system uptime. The SPRINT system has been designed to lower overall total energy consumption through efficient heater use and optimized cooling requirements. The rock solid performer, SPRINT 2.0, now available with low wattage nozzles and manifolds SPRINT 96-cavity hot half Cost savings, realized

15 Precise, all electric injection solution Taking multi-material molding to a new level, the E-Multi all electric, compact injection unit enables multi-shot molding in single shot molding machines, bringing new life to existing capital equipment mm EM4 EM3 EM2 EM1 E-Multi mounting options: 1. Horizontal (side) mount option 2. Vertical (Top) mount option in Precise, energy efficient control The E-Multi unit is designed for multimaterial applications in every market segment, with a precise servo driven screw design that comes in multiple sizes and a variety of options. The all-electric unit offers fast, precise results utilizing a highly energy efficient servo injection assembly, excellent for position and speed control. The integrated, user-friendly control offers an intuitive user interface presented on a multilanguage touch screen. Easily installed and interchangeable The E-Multi was designed to allow for flexible mounting options. The unit is mold mounted, either vertically or horizontally, for maximum usability. The unit is compact in size and setup is easy allowing it to be efficiently interchanged between machines to help streamline production. A variety of options are available including special robot interfaces, material loaders, high wear screw and barrel, extended nozzle assembly and remote/handheld HMI s. This innovative solution provides molders with a magnitude of new molding opportunities. Add value to existing equipment

16 Accurate, responsive and intuitive The new TempMaster M-Series platform delivers state-of-the-art technology with a user-friendly interface, at the lowest cost of ownership. All M-Series models use an advanced proprietary control algorithm, current monitoring, group fault detection and power thermocouple. Designed to optimize any hot runner system. TempMaster M1 The TempMaster M1 controller boasts a minimum footprint with the advanced features of a touch screen unit. It s adjustable touch screen includes diagnostics technology that optimizes hardware configuration and performance. The unit is plug and play, making it extremely user-friendly with quick start-ups that reduce scrap and energy usage. The unit is available in 6,12, 24 and 48 zone configurations, with 6 zone cards at 15 amps per zone. Future-now technology provides advanced accurate measurement, control and feedback. TempMaster M2 The TempMaster M2 controller, with its touch-screen technology and built-in LAN capabilities, is designed for maximum flexibility. Control up to 232 zones using the system s easy-toaccess graphs, drawings and Tool-Store. Several zones can be selected, grouped and controlled at the same time. Actual control meters can be viewed live and monitored anywhere on the system. Troubleshooting is swift and simple. Automatic tuning criteria can manage even the most challenging applications, while the auto-diagnostic routine can easily test your mold. TempMaster Mt The TempMaster MT line of hot runner temperature controllers provides superior accuracy for 2 to 18 control zones. The MT control technology includes a digital micro-processor, touch screen and multiple process indicators. The TempMaster MT operator interface is easy to use, features clearly legible numbers and instantly recognizable graphic operator commands. Advanced control technology that ensures improved results

17 The M-Series designed for ease of operation. Although each of the M-Series controllers offer features that are suited to specific applications, all of the units share common user-friendly interfaces. Right out of the box, the controller is easily setup and connected. Each unit has a touch screen that varies in size but still offers intuitive control programming. From interactive 3D graphing, system details and picture viewing, there are endless options that allow the user to customize their controller screen. The plug and play system architecture ensures a minimal learning curve for operators. Plus, each M-Series controller comes with proprietary Future-now technology, a state of the art algorithm only offered by Mold-Masters that has optimized molding processes all over the globe. High quality, robust and durable, the M-Series models standout as key tools ensuring sustainable plastic processing performance. Zones: 4 Zones: 6 Zones: 12 Zones: 18 M1-S Zones: 12 M1-L Zones: 48 MT-XS MT-S MT-M MT-L TempMaster Mt model options TempMaster M1 model options TempMaster M2 model options M2-XS M2-S M2-M M2-L Zones: 36 Zones: 72 Zones: 144 Zones: 216

18 An answer for every application Mold-Masters offers an endless array of customized solutions and has earned a reputation for solving the most technically challenging applications. TM engineered to your needs Whether it is demanding resins, gate positioning or part design challenges, our products and knowledge will help you find a solution. Using an extensive database of custom nozzles and the solid foundations of the Master-Series product line, Mold-Masters can build a customized solution to suit any application stack Master-Series Femto hot runner system and hot half Stack Molding Stack mold solutions are available with solid sprue bars or Melt-Link valve-to-valve melt transfer systems. Melt-Link provides free access across the first parting-line for part handling, reduced shear rates and lower pressure drops. Stack mold systems are available in hot-tip, offset or back-to-back valve gating. Mold-Masters supplies hundreds of multi-material solutions every year. From multi-color to multi-material to co-injection barrier, we have a solution tailored to any need. By using unique iflow manifold technology to create optimized flow paths that house multiple materials, these systems can be made up to 25% thinner than conventional systems when combined with the E-Multi electric injection unit, a turn key multimaterial solution for conventional injection molding machines. Engineered to solve your toughest molding challenges

19 Innovative service and support MasterCARE is a dedicated team of industry experts, specially trained to help solve challenges. For routine service, troubleshooting or just answering questions, your local MasterCARE field technician is at your disposal. With service centers on all continents, parts are easily accessible within 24 hours. We focus on delivering your hot runner in days, not weeks using our global design and manufacturing capacity, design automation, manufacturing automation and our Enterprise Resource Planning (ERP) system. With a wide array of nozzle and manifold combinations, all available in completely flexible pitches, MasterSpeed delivers in your time frame. Our unique STAMP business model dedicates a team of our best technical and project management staff to our global clients for successful and timely program execution. STAMP teams: Establish the client s key project deliverables including cycle, part quality and processing conditions. Use advanced analysis tools and industry knowledge to ensure sound technical solutions. Employ advanced project management tracking and reporting tools. Provide technical support during commissioning of molds. Ensure synchronized global account management of concurrent projects. Your hot runners. Online. Anytime. With the click of your mouse you can design, quote, order and track your hot runner system, 24 hours a day, 7 days a week. Merlin guides you through a step-by-step process to configure your runner system. When the design is complete, download comprehensive general assembly drawings for use in your mold concept. Detailed information such as pricing and lead times is available instantly. Ordering is made simple with descriptive part lists and bills of material at your fingertips. Plus, Merlin keeps track of your order history, so you can re-order with ease. At Mold-Masters, we stand firmly behind our belief that the best hot runner solution provides reliable performance over the life of the mold. As a result, we offer an unprecedented 10-year warranty. No other hot runner supplier can compare with clamped on heater technology. We define our success by yours

20 Global Headquarters - Canada Mold-Masters (2007) Limited tel: fax: [email protected] Brazil Mold-Masters do Brasil Ltda. tel: fax: [email protected] Mexico MM Hot Runner Injection México, S.A. de C.V. tel: fax: [email protected] U.S.A. Mold-Masters Injectioneering LLC tel: fax: [email protected] European Headquarters - Germany Mold-Masters Europa GmbH tel: fax: [email protected] Austria / East and South East Europe Mold-Masters Handelsges m.b.h. tel: fax: [email protected] France Mold-Masters France tel: +33 (0) fax: +33 (0) [email protected] Spain Mold-Masters España tel: fax: [email protected] United Kingdom Mold-Masters (UK) Limited tel: (0) fax: (0) [email protected] Asian Headquarters - China Mold-Masters (Kunshan) Co, Ltd. tel.: fax: [email protected] India Mold-Masters Technologies Private Ltd. tel: fax: [email protected] Japan Mold-Masters K.K. tel: fax: [email protected] Korea Mold-Masters Korea Ltd. Tel: Fax: [email protected] Singapore Mold-Masters Singapore PTE Ltd. tel: fax: [email protected] Mold-Masters and the Mold-Masters logo are registered trademarks of Mold-Masters (2007) Limited A Milacron Company. All rights reserved. E7005-5