opti-flo incoe north america hot runner · pdf fileopti-flo ® hot runner systems i...
TRANSCRIPT
Opti-Flo® Hot Runner SystemsI Designed for Performance
For more information visit www.incoe.com/optiflo
Proven AdvantagesWith numerous applications in full production
globally, Opti-Flo® technology delivers proven,
outstanding performance advantages.
The Opti-Flo® result: Superior cavity-to-cavity
consistency and repeatable part quality.
Opti-Flo® Hot Runner Systems Opti-Flo® systems offer molders significant processing advantages available only from INCOE®.
In our exclusive partnership with Beaumont Technologies Inc., INCOE®’s Opti-Flo® hot runner
systems utilize the patented MeltFlipper® melt rotation technology developed by BTI.
Engineered PerformanceThe Opti-Flo® design, incorporated in select INCOE® manifolds,
is the first scientifically engineered hot runner system as it is
both geometrically and rheologically balanced to ensure
equal flow conditions and consistent cavity filling.
The Opti-Flo® system reduces or eliminates
artificial balance techniques such as adjusting
nozzle heater temperature in order to balance
cavity filling.
Technology
with
The products shown may be covered by one or more of the following Beaumont Technologies Inc. U.S.A. patents : 6,077,470; 6,503,438.
Registered ISO 9001:2000 © 2011 INCOE Corporation EN-06/2011
INCOE® North AmericaINCOE® Corporation 1740 East Maple RoadTroy, Michigan 48083USA
Main: T: +1 (248) 616-0220 F: +1 (248) 616-0225 E: [email protected]
Sales: T: +1 (248) 556-7770 F: +1 (248) 616-0227 E: [email protected] Support: T: +1 (248) 556-7790 F: +1 (248) 556-7799 E: [email protected]
INCOE® EuropeINCOE® International EuropeCarl-Zeiss-Straße 47D-63322 Rödermark Germany
Sales & SupportT: +49 (0) 6074-8907-0F: +49 (0) 6074-8907-310E: [email protected]
INCOE® SingaporeINCOE® Singapore Pte Ltd.8, Boon Lay Way #03-02TradeHub 21609964 SingaporeSingapore
Sales & SupportT: +65 (6) 515-5300F: +65 (6) 861-1163E: [email protected]
INCOE® China | Dongguan Branch OfficeINCOE® Hotrunners (Shanghai) Co., Ltd. Room B, 5/F, Hao Yun Building2nd Huan RoadChangan Town, DongguanGuangdong, China
Sales & SupportT: +86 (769) 8535-5881F: +86 (769) 8542-2998E: [email protected]
INCOE® Hong KongINCOE® (H.K.) Ltd.1205 Leader Industrial Centre57-59 Au Pui Wan StreetFo Tan, Shatin, N.T.Hong Kong
Sales & SupportT: +852 2790-8840F: +852 2790-8411E: [email protected]
INCOE® China | ShanghaiINCOE® Hotrunners (Shanghai) Co., Ltd.399 Xuanzhong Road, Building 16Pudong New AreaShanghai 201314China
Sales & SupportT: +86 (21) 5818-6300F: +86 (21) 5818-6303E: [email protected]
INCOE® South AmericaINCOE® International Brasil, Ltda.Rua Eugenio Ulhano, 335Jardim VirginiaItatiba, SP 13257-480Brasil
Sales & SupportT: +55 (11) 4538-2445F: +55 (11) 4524-5690E: [email protected]
www.incoe.com
High Shear/Low Shear SeparationAfter the material flow enters the hot runner system through the manifold nozzle (Fig. 1), it
splits left and right at the first intersection at the primary runner channel (Fig. 1A). This action
places high sheared material at one side of the flow channel and the low sheared material on
the opposite side. When the material is split again at the
next intersection or secondary runner, but on the same
plain in the manifold, the material is rotated 90 degrees
biasing the high sheared material to the inside channel
wall. The low sheared material is biased to the opposite.
At the tertiary runner division the high sheared material
is again rotated so that it is now concentrated to flow
to the inside flow channel. As the viscosity is now
considerably different, those cavities at the ends of each
flow channel fill at different rates (Fig. 1B).
Fig. 1
Fig. 1A
Fig. 1B
Desi
gned
for P
erfo
rman
ce
Flow Imbalances Reduce Your Bottom LineNegative effects of shear induced imbalance can cause uneven cavity filling, and inconsistent
part quality which significantly reduce your ability to compete. Balanced material flow is not
only achieved through geometric design. Through research, the reasons for these negative
effects are identified in the following text. Opti-Flo® systems offer a complete, engineered
solution to resolve processing issues before production begins.
The Opti-Flo® SolutionUtilizing Opti-Flo® technology, INCOE® hot runner systems can significantly reduce the shear induced flow
imbalance (Fig.5). Extensive testing has been completed demonstrating the outstanding performance of the
Opti-Flo® system. A design of experiments was performed using a variety of plastic. Testing was conducted
utilizing an industry standard hot runner design and an INCOE® Opti-Flo® hot runner system. The results
demonstrated shear induced flow imbalances reduced to less than 4% with the Opti-Flo® hot runner system.
Other benefits realized are reduction of fill and pack pressure, a wider processing window, and consistent
dimensional properties.
Return On Investment To ProfitReturn on investment begins immediately. Given the fact that many molding applications cannot afford even
one imperfect molded part, the Opti-Flo® system provides the assurance (and payback) that conditions start
out at the very beginning of the injection molding process to make quality molded parts. Benefits include:
• Uniform Part Weights
• Uniform Part Dimensions
• Uniform Mechanical Properties
• Scrap Reduction
• Cycle Time Reduction
• Setup Time Reduction
• Simplified Processing Requirements
• Improved Part Quality to Customers
• Faster Part Qualification Process
Flow GroupsIn the single level 8 drop system shown, flow is divided in the primary runner and is split into 2 flow groups at the
secondary runner intersection; Flow 1 (red) is highly sheared material, and Flow 2 (yellow) is low sheared material. The
divided shear in the primary runner and subsequently
separation at the primary and secondary intersections
causes the inside cavities (Flow 1) to fill first since it flows
faster due to a lower viscosity. Increasing cavitation also
increases the number of flow groups at each runner
intersection. Likewise, stack-molding applications exhibit
the same shear imbalance characteristics. Sheared material
is typically directed toward the inside parting line cavities
(Flow 1), which fill first.
Effects Of Shear In Simple ApplicationsA simple example of shear induced imbalance is shown here (Fig. 2).
Sheared material is created in the machine nozzle and the inlet nozzle of
the manifold. At the primary runner, in this case the only runner, the high
sheared material that has been divided, will flow to the outer portion
of each cavity creating an intra-cavity imbalance. This can lead to core
shift as well as other part defects. With an INCOE® Opti-Flo® hot
runner system (Fig. 3), the melt is repositioned at the intersection, so the
high sheared and low sheared materials arrive in equal proportion to
achieve uniform cavity filling.
Increased ComplexityHot runner systems often require level
changes in order to provide geometric
balance. As depicted to the right (Fig. 4),
what results is shifting the imbalance from
the inside cavities (which would have
resulted in a single level manifold design),
to the outside cavities.
Fig. 2
Fig. 3
Technology
with
Shear Induced Flow ImbalanceFlow imbalance is a direct result of the shearing effect common to the basic flow
properties of molten plastic. Shear is developed due to laminar flow. As flow occurs
in the sprue and runner channel, highly sheared material is deposited near the walls
of the flow channel.
This highly sheared
material becomes
less viscous than the
remaining melt flow
and is the cause of
filling imbalances.
LOW SHEAR ZONEANNULAR
HIGH SHEAR ZONE
STACK MOLD SYSTEM
FLOW 1
FLOW 1
FLOW 1
FLOW 1FLOW 1FLOW 2
FLOW 1FLOW 2
FLOW 2
FLOW 2
FLOW 2
FLOW 2
SINGLE LEVEL SYSTEM
Fig. 5
Your competitive advantage exclusively available on INCOE®’s Opti-Flo® systems
Fig. 4