K 2001: Nozzles for every occasion and more

Not only was there a plethora of breathtaking molds running in machines at K 2001, but there was also a strong contingent of moldmakers showing off their wares at their own stands. Along with them came a number of tooling component suppliers and some noteworthy product introductions. 

Hot Runner Systems 
Korean-based Yudo drew a lot of attention with its new hot runner valve system. The Yuri system combines the nozzle and valve in one body and incorporates Smart Flow technology in the design of its melt channel, all in an effort to minimize pressure drop and help speed color changes. 

Combining the nozzle and valve unit reportedly allows mold height to be reduced significantly. Also, the valve cylinder and valve pin are located under the manifold, so the valve pin is not influenced by the heat expansion of the manifold. This combination design also takes out the bushing, reducing the risk of melt and gas leakage from the valve pin guide bush area. 

The Yuri system is said to eliminate deflection of the valve pin, which is significant when you consider that a valve pin located 300 mm from the center of the nozzle inlet at a temperature of 300C can have a deflection of more than .74 mm in a standard valve gate system. 

The Yuri system is delivered using the company's ezModu system, in which the hot runner system is fully wired and tested prior to shipment. The system is designed to work with pneumatic cylinders; however, a hydraulic system is available in the Yuri 42 Series for large applications. 

Another company offering fully interconnected and wired valve gate systems is Synventive Molding Solutions. The interconnections and wiring may conform either to Synventive's proprietary standards or to the customer's standards. This move was made in response to market demands for faster, more reliable installation and servicing. 

Hasco was also on hand with a complete solution. It has expanded its product line to include turnkey hot runner systems in the form of hot halves. The hot halves are based on standard and custom-made components, and the engineering work is supported by the company's new Moldgate software (available at www.hasco.com). The hot halves are optimized, electrically wired, and ready to be plugged in upon delivery. 

Incoe offered new technology for small and large molds. On the small side is its DF3 miniature hot runner system. The system is well suited for use on circular manifolds for multiple gating within a narrow space. Other reported advantages include individual temperature control of each gate, symmetrical part cooling, and high cavity strength. 

Incoe's DF25 system, on the other hand, is designed for very large systems with large shot weights and very high flow rates. The system can incorporate many popular gate types, including point, sprue, and valve gates, and is available with bushing lengths greater than 700 mm. 

Also new from Incoe, the DMT multitip hot runner system uses the Direct-Flo principle to guide melt directly into the individual injection points. Color is said to change easily. DMT can be used for single and manifold applications; the number of tips on each bushing ranges from two to six. 

Hot Runner Nozzles and Manifolds 
K 2001 saw a number of innovations in hot runner nozzle technology. A universal hot runner with external heating was introduced by Hasco. Called Rapid Shot (also known as Z 3500), the nozzle carries a gate configuration and melt chamber that can reportedly be adapted to any application. The nozzle can also be used for multicavity hot runner molds. Nozzle tips, heaters, and thermocouples reportedly can all be exchanged in the injection molding machine. 

More specific in its application is the small-pitch hot runner nozzle introduced by Mold-Masters. The MIM Dura Atto cartridge heater nozzle is designed for small-part, high-cavitation applications, and reportedly turns the melt channel into an integral heater with an optimized axial profile. Nozzle body diameter is less than 9 mm, providing for minimal gate vestige. This makes the nozzle ideal for products with core diameters greater than 16 mm, such as lipstick caps, medical products, and container caps, reports the company. 

Günther introduced several new hot runner nozzles. Its Micro flat nozzle is designed for use with flame-retardant materials. Nozzle cavity distances starting from 7.62 mm are possible. With needle valve applications, the distance is from 9 mm. At K, the nozzle was shown in an eight-cavity needle valve system. 

The company also developed a new 230V single nozzle, which offers strengthened heater capacity in the nozzle head. The construction reportedly lessens the thermal load on the plastic being used, and works well with high-temperature plastics. 

Günther has also developed a new type of manifold heater. The thick-film manifold heating elements are high-tensile steel plates that can be fixed on the outer surface of the hot runner manifold. This reportedly provides even heat distribution. In the future, the company plans to use this technology for nozzles, allowing it to make small-diameter nozzles for low voltage and 230V applications. 

Hot Runner Temperature Control 
A new family of hot runner temperature control systems is now available from Gammuflux. The TTC family is said to offer tighter temperature control through enhanced control algorithms, which allow adaptive control of each zone. TTC models can handle from 12 to 256 zones. 

The system sports a modular design, and is reportedly easily accessible by modem for troubleshooting. The TTC family is also readily designed for global installation with expanded language conversion options, universally accepted icons, and input power flexibility. 

A panel-mount option is also available. The TTC 2200 panel-mount system marks the first time Gammaflux has offered such technology that can be seamlessly integrated into the molding machine control panel. The TTC can be operated using the customer's own machine controller or with the Gammaflux TTC touch-screen monitor. 

At K, the TTC was in action at the Husky booth. Gammaflux representatives say this family marks a move by the company to be more price competitive. The panel system, for example is said to be "almost half the cost of currently available technology." 

A newly designed series of hot runner temperature control units is also available from Hasco. The Z 122/1 microprocessor controller has up to nine control circuits. Each circuit has a power consumption of 3600W. Standard features include automatic temperature reduction, boost function, programmable starting circuit, and more. 

Multizone controllers were also introduced by Hasco. The self-optimizing controllers offer up to 96 control points, which can all be controlled simultaneously. 

Tooling Components 
Of course, not everything related to tooling at K revolved around hot runner technology. A new mixing nozzle, designed for additional melt homogenization, was introduced by Koch-Glitsch. The KMN nozzle is said to have a 30 to 50 percent lower pressure drop compared with earlier designs. Nearly all current polymers can be processed by this mixing nozzle, reports the company. 

The newly developed KSM mixer is the heart of the mixing nozzle, and is installed directly into the nozzle. The technology reportedly results in streakless colorant distribution, even at low concentrations. The KMN mixing nozzle is available in diameters of 12, 17, 22, 35, and 50 mm. 

Herzog announced at K that its HP nozzle, which was introduced in Europe in mid-2001, is now available in the U.S. The nozzle is designed to withstand high injection pressures and is said to reduce shear sensitivity and pressure drop. 

For the demolding of internal threads and internal undercuts, Hasco introduced a newly designed collapsible core. The Z 3600 is suitable for single- and multicavity molds, and offers a compact design. Collapsible segments use a dovetail design and are constructed of D-2 steel. Unlike an unscrewing system, the collapsible core does not rotate, but is activated by the mold action. The cores are available in seven diameters, ranging from 12 to 55 mm. 

Hasco also launched a quick-change mold system for use in prototyping. The system consists of standard mold frames, corresponding inserts, and an adapted ejector assembly. It's offered in three sizes: 156 by 196 mm, 246 by 296 mm, and 296 by 396 mm. The mold frame is constructed of #2 steel, and inserts are offered in 4340 steel or 7075 aluminum.