Molded plastic, ejection runners

The feed system is an unwanted by-product of the molding process, so a further requirement is to keep the mass of the feed system at a minimum to reduce the amount of plastic used. This last consideration is a major point of difference between cold and hot runner systems. The cold runner feed system is maintained at the same temperature as the rest of the mold. In other words, it is cold with respect to the melt temperature. The cold runner solidifies along with the molding and is ejected with it as a waste product in every cycle. The hot runner system is maintained at melt temperature as a separate thermal system within the cool mold. Plastic material within the hot runner system remains as a melt throughout the cycle, and is eventually used on the next cycle. Consequently, there is little or no feed system waste with a hot runner system. Effectively, a hot runner system moves the melt between the machine plasticizing system and the mold to a point at or near the cavity(s).3 32> 326-332,490... 

Runners are the ehannels through which the polymer melt is fed into the mold cavities from the eyhnder nozzle. In a multicavity mold, it is necessary to fill all the mold cavities simultaneously and uniformly. Control of the size of the runners provides a means of controlling the flow resistance and balaneing the flow into the mold cavities. In most multicavity molds, the runners form part of the mold flame. Consequently, the ejected part is accompanied by the runner system, which must be removed and, in the ease of thermoplastics, reground for reuse. The use of the hot runner mold whereby the runner ehannels are heated to keep the polymer in the molten state, eliminates this need for plastic runner separation and avoids possible generation of scrap material. With proper machine operation, a hot rurmer mold requires a smaller amoimt of melt per shot than an equivalent cold runner mold, leading to redueed injeetion time and faster cycles. 

The hydraulic pressure or mechanical pressure is applied to make sure all of the cavities within the mold are filled. Plastics are allowed to cool within the mold. The mold is opened by separating the two halves of the mold. The product is ejected from the mold with ejecting pin. The runners and sprue are trimmed off and recycled. 

Under transfer molding, the mold is first closed. The plastic material is then conveyed into the mold cavity under pressure from an auxiliary chamber. The molding compound is placed in the hot auxiliary chamber and subsequently forced in a plastic state through an orifice into the mold cavities by pressure. The molded part and the residue (cuU) are ejected upon opening the mold after the part has hardened. Under transfer molding, there is no flash to trim only the runner needs to be removed. 

Hot-runner mold (insulated-runner mold) n. An injection mold for thermoplastics in which the runners and sometimes the secondary sprues are insulated from the chilled cavity plate so that they remain hot during the entire cycle. The plastic in the runners remains molten and is not ejected with the molded part, thus avoiding the normal handling, grinding, and reprocessing of sprues and runners. 

Figure T.8 Transfer molding process (a) the mold is closed and material is placed in the pot, (b) the plunger descends into the pot, causing material to melt and flow through runners into cavities, (c) after cure, the press opens, the plunger retracts and the parts are ejected with cull and runners. (Ref Hull, J.L., Processing of Thermosets , Modern Plastics Handbook, CA. Harper, ed., McGraw-Hill, New York, 2000)...

Similar to die casting of metals. A thermoplastic molding compound is heated to plasticity in a cylinder at a conti-olled temperature and forced under pressure through sprues, runners and gates into a mold the resin solidifies rapidly, the mold is opened, and the parts ejected with certain modifications, thermosetting materials can be used for small parts. 

In injection molding, the fiberglass and resin system are introduced into a heating chamber where the mixture softens and is injected under pressure into a nmtched-metal mold cavity. The material then cools and solidifies into its intended shape. It is then ejected from the mold and trinuned of runners and flash if necessary. The mold may consist of a single cavity or a number of similar or dissimilar cavities, each connected to flow channels (runners) which direct the melted plastic to the individual cavities. 

Injection molding technology involves the injection of molten plastic into one or several cavities via a hot-runner system (melt-channel distribution system) and rapid cooling of a preform to a low temperature. At this point the freshly manufactured article can be ejected from the cavity. In multilayer technology, more than one plastic resin is injected into the cavity. 

---