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HRSflow has supplied two hot runner systems to a Tier One automotive supplier to produce Class A rear-quarter windows.

The polycarbonate windows, produced via a two-component injection moulding process by Chinese supplier, Shentong, are destined for the Buick GL8 and GL8 Avenir MPVs (multi-purpose vehicles) and, with dimensions of 1200 mm x 460 mm, are said to be the largest of this type at present.

One of the hot runner systems is used to produce a transparent first component and the other for the partial overmoulding with a dark-coloured PC around the edges. Both systems integrate HRSflow's programmable FLEXflow valve gate technology, which the company says enables the manufacturer to achieve the outstanding surface quality specified by the OEM for these parts.

By using FLEXflow the windows--which are around 40 percent (3kg) lighter than comparable parts made of glass--have high fitting precision for problem-free assembly, with minimum warpage and tight tolerances.

The two hot runner systems developed by HRSflow each have a hot runner manifold with ten servoelectrical drives for the nozzles with conical valve gate, integrated into the clamp platen. The FLEXflow technology used to control the sequential injection process is said to make it possible to coordinate every single individually driven needle precisely to the process, and to open and close it with selectable speeds. This, says HRSflow, allows absolute precision control both of the melt flow in the individual hot runner nozzles and of the volume flow in the overall cavity so that it is filled evenly and homogeneously.

Thanks to the gentle opening and closing of the needles, undesired pressure drop or changes in temperature and flow velocity that can occur with conventional cascade injection moulding because of abrupt switching on of the hot runner nozzles is eliminated. This also eliminates unsightly flowmarks on the moulded part. The overall result, says HRSflow, is a Class A moulding surface with no optical defects.

The main applications of the FLEXflow technology are the injection moulding of high-quality complex automotive parts including large-area exterior and interior components such as spoilers, front ends, instrument panel supports, door trim and headlights as well as wide trunk taillights, plus the rear-quarter windows described here made of transparent polycarbonate (PC).



Thysis Technical Mouldings, based near York, has installed a new, centralised system for materials handling and drying.

The new modular system includes a central loader and bank of dehumidifier driers provided and installed by Intelicare, UK agents for Italian manufacturer, New Omap srl.

Intelicare says the system can control up to 40 material receivers and four vacuum blowers. Material is conveyed to the receivers using dehumidified air. Vacuum blowers may be side channel, multi-stage or lobed and are sized according to the required airflow, distances and material throughput. At Thysis, suitably-sized cyclone filters have also been installed in addition to the large centralised filter to both protect the blowers and prevent the circulation of dust in the workplace.

The equipment installed at Thysis comprises a centralised feeding system to the injection moulding machines, a 5.5kW vacuum blower with cyclone and large cloth filter, insulated hoppers and line clearance valves to each material line. In addition, two dehumidifier dryers are installed; a WDM 270 Honeycomb rotating drum dryer feeding two 300 litre hoppers, each with receiver and a MDM 500 Desiccant dryer feeding two 600 litre hoppers, each with receiver.

"Material throughput per hour has increased, rejects have reduced, the finished product quality and appearance has improved significantly and the workplace is permanently clean and tidy" said Terry Goodwin, Thysis' Technical Director.



Hasco has launched a new range of fully assembled and wired hot runner systems designed for improved efficiency in moulding operations.

New H4016 hot runners provide a robust, form-fit connection between the hot runner manifold and the screw-in nozzle, which, says Hasco, guarantees leak-free operation and significantly facilitates the mounting and removal of the system as a whole in the injection mould.

Additional advantages, it added, include the assembly and electric wiring of the complete hot runner system. The connector cables for the individual nozzles and the hot runner pass through individually configured cable ducts to the connection box, where they are wired up according to a customer's specifications. This saves the mouldmaker or injection moulder from having to connect up the system and ensures a smooth start to production. The correct allocation of the zones to the manifold heating units and nozzles is documented on a dimension sheet for the user.

This system layout, says Hasco, considerably facilitates its mounting and removal and prevents any damage to the hot runner system when the mould is being serviced. Attachment points on the manifold mean that it can be readily lifted out of the cavity, avoiding any distortion of the system when it is tilted during installation or removal.

The systems are designed and produced in close cooperation with the customer, making allowance for thermal expansion and the ratio of the hole spacing to the nozzle length. Hasco says it "guarantees dimensional stability, correct electrical wiring and a tight seal between the nozzles and the manifold in order to prevent leakage of the melt."

In conjunction with Hasco's new Vario Shot H6500 nozzle series, Hasco says users receive a hot runner system that they can easily and securely mount themselves. The H4016 wired hot runner systems constitute an optimum compromise between mounted systems and hot halves, it added, offering an "attractive price to performance ratio and ensure agility through their very short delivery times."



Synventive, a business of Barnes Molding Solutions, has completed an expansion project of its facility in Suzhou, Jiangsu Province, China, enhancing its production capacity for advanced hot runner systems.

Synventive is a global leader in manufacturing of hot runner systems, components, and valve gate control technologies. The upgraded and expanded facilities enable Synventive to meet growing demand for moulding solutions in the Asia Pacific market.

Synventive's plant expansion is part of Barnes Group's efforts to accelerate development of its moulding business in the Asian market. In 2015, Barnes Group established the new Barnes Moulding Solutions strategic business unit, which presently consists of subsidiary companies Synventive, Manner, FOBOHA, Thermoplay, Priamus, and Gammaflux.

The new facility is adjacent to Synventive's current plant in Suzhou. The company's capacity at this site will increase significantly to meet rapid growth in demand.

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Publication:British Plastics & Rubber
Date:Jan 1, 2018
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