Hot Runner Solutions and Control Systems - Mold

Hot Runner Solutions and Control Systems
Canada
USA
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
Brazil
Germany
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.
Serving All Key Markets
innovation
»» Automotive
»» Medical
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.
»» Caps/Closures
»» Packaging
»» Electronics
»» Personal Care
»» Housewares
»» Technical
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.
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
and reliability
Hot Tip Gating
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
4
3
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.
1
Optional tips and seals are available
for aggressive and corrosive resins.
Master-Series nozzles withstand up
to 3,000 bar (44,000 psi) injection
pressures. The flange (3) is designed
»»
Brazed in heaters provide uniform and consistent heating
6
5
2
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
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.
2
4
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.
iFlow manifold
technology
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.
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.
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.
»»
iFLOW vs Gun Drilled Channels on Color Change 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
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
Synchro- plate and e-Drive
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.
Synchro-Plate solutions are available
when the pitch between cavities is too
tight to use individual pistons. SynchroPlates are available with pneumatic,
hydraulic and electric actuation.
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.
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
1
»»
E-Drive
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
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),
»»
Example of 45 degree
Melt-Disk option
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).
»»
MD85 showing individual gate shut-offs
Melt-Start™ temperature controller
software to automatically implement
the correct start-up and shut-down
sequence on all components
of the system.
1
2
3
4
»»
Example of 60 degree
Melt-Disk option
»»
Melt-CUBE
2
1
3
4
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
A Design optimized for
Field Use
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.
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
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.
Engineered for speed
Purpose engineered hot runner systems for ultra fast, high performance closure molding.
»»
Cost is Key
Quality Parts
Lifecycle Cost Savings
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.
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.
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.
»»
64 Cavity Sprint E-Drive Valve Gate
System engineered for CSD closure
applications
SPRINT
96-cavity
hot half
Cost savings, realized
The rock solid performer, SPRINT 2.0,
now available with low wattage
nozzles and manifolds
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.
2310
91.0
2200
86.6
2000
78.7
1795
70.7
1550
61.0
1400
55.1
1240
48.8
1000
39.4
800
31.5
600
23.6
400
15.7
200
7.9
0 mm
0 in
▲
EM4
▲
EM3
▲
EM2
▲
EM1
E-Multi mounting options:
1. Horizontal (side) mount option
2. Vertical (Top) mount option
1.
2.
Add value to existing equipment
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.
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
TempMaster M2
TempMaster Mt
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.
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.
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.
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.
Advanced control technology that ensures improved results
▲ M1-S
▲ M1-L
Zones: 12
Zones: 48
▲ M2-XS
Zones: 36
▲ M2-S
Zones: 72
▲ M2-M
Zones: 144
▲
▲
▲
Zones: 18
▲
Zones: 12
▲
Zones: 6
MT-XS
MT-S
▲
Zones: 4
▲
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.
MT-M
▲
The M-Series – designed
for ease of operation.
MT-L
▲ M2-L
Zones: 216
»»
TempMaster Mt
model options
»»
TempMaster M1
model options
»»
TempMaster M2
model options
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.
engineered to your needs
Stack Molding
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 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.
»»
48+48 stack Master-Series Femto
hot runner system and hot half
TM
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
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
Asian Headquarters - China
Global Headquarters - Canada
European Headquarters - Germany
Mold-Masters Europa GmbH
tel: +49 7221 50990
fax: +49 7221 53093
email: [email protected]
Mold-Masters (Kunshan) Co, Ltd.
tel.: +86 512 86162882
fax: +86 512 86162883
email: [email protected]
Brazil
Mold-Masters do Brasil Ltda.
tel: +55 19 3518 0699
fax: +55 19 3518 0699
email: [email protected]
Austria / East and South East Europe
Mold-Masters Handelsges m.b.H.
tel: +43 7582 51877
fax: +43 7582 51877 -18
email: [email protected]
India
Mold-Masters Technologies Private Ltd.
tel: +91 422 423 4888
fax: +91 422 423 4800
email: [email protected]
Mexico
MM Hot Runner Injection México, S.A. de C.V.
tel: +52 728 282 48 33
fax: +52 728 282 47 77
email: [email protected]
France
Mold-Masters France
tel: +33 (0) 1 82 05 00 80
fax: +33 (0) 1 82 05 00 83
email: [email protected]
Japan
Mold-Masters K.K.
tel: +81 44 986 2101
fax: +81 44 986 3145
email: [email protected]
U.S.A.
Mold-Masters Injectioneering LLC
tel: +1 586 752 6551
fax: +1 586 752 6552
email: [email protected]
Spain
Mold-Masters España
tel: +34 93 802 36 01
fax: +34 93 802 49 08
email: [email protected]
Korea
Mold-Masters Korea Ltd.
Tel:+82 2 2082 4755
Fax:+82 2 2082 4756
email: [email protected]
United Kingdom
Mold-Masters (UK) Limited
tel: +0044 (0) 1432 265768
fax: +0044 (0) 1432 263782
email: [email protected]
Singapore
Mold-Masters Singapore PTE Ltd.
tel: +65 6261 7793
fax: +65 6261 8378
email: [email protected]
Mold-Masters (2007) Limited
tel: +1 905 877 0185
fax: +1 905 873 2818
email: [email protected]
www.moldmasters.com
Mold-Masters® and the Mold-Masters logo are registered trademarks
of Mold-Masters (2007) Limited © 2013. A Milacron Company. All rights reserved. E7005-5