Design Guidelines

Design Guidelines
Design Guidelines Cavity Design

To maximize the integrity and life of the gate area, various factors must be considered: Recessed Gate Areas When designing gates into recessed areas such as dimples, a generous radius should be incorporated to avoid extended thin sections of plate steel (see figure at right). Nozzle Seal Off Diameter To provide a durable nozzle seal diameter surface in the gate bubble, a surface hardness range between 49 - 53 Rc is recommended (see figure at right). If softer materials are used (e.g. BeCu), these should be hard chrome plated to increase hardness. Gate Steel Hardened tool steels such as 49 - 51 Rc AISI H13/DIN 1.2344 provide a good combination of strength and ductility. EDM Process It is not recommended to EDM (electro-discharge machine) the gate area. A hardened surface layer resulting from the EDM procedure makes the steel increasingly brittle, potentially leading to premature gate failure. It is also good practice to machine the gate hole after hardening to avoid brittleness, caused by rapid quenching. Gate Cooling Gate area cooling is required to remove excess heat generated by the system. Sufficient cooling provides many benefits including: Consistent gate quality Consistent gate vestige Greater control over material stringing Greater control over resin drool Gate Cooling Greater control of gate blushing Faster cycles
Nozzle Seal Off Diameter
Thin Section
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines
Optimized Gate Cooling (Key Elements) 1) Minimize the distance from the cooling channel to the gate detail The maximum recommended distance between the cooling channel and the gate detail is 3 times the cooling channel diameter. 2) Cooling should surround the insert. The cooling water should reach flow speeds that cause effective mixing of the fluid. For most inserts, a flow rate of about 6.8 - 8.3 liters (1.8 - 2.2 gallons) per minute is sufficient. 3) The gate insert material affects heat dissipation and longevity. Insert materials such as H13 (material of choice) and 420 SS are 7x less heat conductive than BeCu Alloys. The trade-off with conductivity is hardness and gate life. Material choice will depend upon the number of projected cycles and the cycle time goals, Extended Tips Should not have cooling in front of seal ring * Minimum of 1-1.5X cooling diameter clearance to nozzle bore ** Position the cooling centerline at the mid-point of the seal ring locating diameter
*
Seal Ring
**
Independent Circuits The cavity plate cooling circuit should be independent of the manifold plate cooling circuit. This prevents coolant from leaking onto the hot runner components whenever the plates are separated.
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Design Guidelines
Gate Inserts Gate inserts provide an effective method of cooling the gate area, since the entire circumference is cooled. Cooling circuits for the gate insert should be independent from the plate cooling circuit to provide better control. The gate insert is a replaceable wear item. Gate Insert
Gate Cooling
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Design Guidelines
Cavity Plate Interface Bolts Cavity plate interface bolts are used to fasten the cavity plate to the hot runner. Hot Half The interface bolts should be installed from the clamp (moving) side of the cavity plate, to enable separation of the cavity plate while the mold is still secured within the machine press. Latching Nozzle tips, nozzle thermocouples, nozzle heaters, and nozzles are replaceable while the hot runner remains in the press, minimizing downtime when performing maintenance. Cavity Plate
Interface Bolts
Cavity Plate
Latch
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Design Guidelines
Machine Interface
Machine Nozzle Requirements To prevent pressure loss, dead spots, and to provide a leak-free seal, the mating surfaces and orifice diameters of the machine nozzle and sprue bushing must match. To optimize hot runner performance, the sprue bushing orifice should be the same diameter as the primary sprue bushing flow channel. Restricted Size Optimal Size (preferred)
Sprue Bushing Shut Off Nozzle Resin decompression within the hot runner melt channels is required for each molding cycle. Resin decompression is essential for controlling gate vestige and minimizing material stringing. Husky recommends that a shut-off nozzle be incorporated onto the machine injection unit. The shut off nozzle: Allows screw recovery after decompression without re-pressurizing the melt within the hot runner system. Enables screw recovery during mold open, which may lead to reduced cycle times.
Melt Filters Melt filters are used to screen out any contaminants that may be present within the melt. However, melt filters increase pressure loss, and can prevent material decompression. Melt filters are not recommended when molding small parts, since decompression is essential for producing consistent small gate vestige.
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Design Guidelines
Hot Runner Plate Design Guidelines
Stainless steel is the preferred material for plate manufacture. Suitable steel types are listed below: Type AISI 4140 AISI P20 AISI 420 DIN 1.2316 Manifold Pocket / Pillar Support Husky recommends that a pocket be machined into the manifold plate for the manifold. The manifold pocket: Allows close positioning of the plate bolts to the nozzle components, minimizing plate deflection. Provides superior structural support for the mold and cavities. Manifold Manifold Pocket Hardness (Rc) 30 - 35 Rc 30 - 35 Rc 30 - 35 Rc 30 - 35 Rc
An air gap should be maintained between the manifold and manifold pocket to thermally insulate the manifold from the surrounding plates. The structural rigidity of the design is increased with the incorporation of pillar supports. Pillar supports: Resist manifold plate deflection, by absorbing machine clamping pressure. Pillars allow additional fastening of the manifold plate to the backing plate within the manifold pocket.
Plate Bolt (see chart following page)
Manifold Plate
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Design Guidelines
Plate Bolting To maintain constant seal-off and minimize plate deflection, bolts should be positioned around each nozzle drop and along the outside plate perimeter. Recommended Quantity Per Drop Ultra 500 Ultra 750 Ultra 1000 1.0 (All Pitch) N/A N/A 0.75 (Small Pitch) N/A N/A 1.0 (Large Pitch) 0.5 (Small Pitch) 3 (All Pitch) 3 (All Pitch) 0.75 (Large Pitch) N/A 3 (All Pitch) 3 (All Pitch) N/A 3 (All Pitch) 3 (All Pitch)
Bolt Size M8 (5/16 UNC) M10 (3/8 UNC) M12 (1/2 UNC) M16 (5/8 UNC) M20 (3/4 UNC)
Ultra 250 1.0 (All Pitch) 0.75 (Small Pitch) 1.0 (Large Pitch) 0.5 (Small Pitch) 0.75 (Large Pitch) N/A N/A
Ultra 1250 N/A N/A 3 (All Pitch) 3 (All Pitch) 3 (All Pitch)
The quantity and size of bolts assigned to each drop location is dependent upon the nozzle series and the number of drops (see table above). For systems greater than 12 drops, it is acceptable for drop locations to share drop bolts.
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Design Guidelines
Plate Cooling
Plate cooling circuits maintain a uniform mold plate temperature and match thermal expansion of the mold plates. To design a uniformly cooled mold, consideration must be given to the cooling circuit layout, number of channels, lengths, and diameters. Typical cooling circuit layouts for 2, 4, 6, and 8 drop systems are provided below.
2 Drop
4 Drop
6 Drop
8 Drop
The cooling circuit should be routed around areas of high heat transfer, while maintaining a minimum material thickness of 5,0 mm (0.20") between the cooling line and other features.
5,0 (0.20")
5,0 (0.20")
3,0 (0.12")
Thermal Gate
Valve Gate
Backing Plate Cooling
Manifold Plate Cooling

5,0 (0.20")
5,0 (0.20")
5,0 (0.20")
NOTE: Avoid routing water lines in a manner that would result in uneven cooling of the nozzles and cavities.
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Design Guidelines
Wire Grooves
Power and thermocouple wires are typically routed to the electrical connectors within wire grooves. Wire grooves: Protect the machine operator from live wires. Provide orderly routing of hot runner wires. Prevent potential wire damage. Wire Grooves
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Design Guidelines
Service Connections
ELECTRICAL A hot runner requires a number of service connections such as electrical for heaters, water for plate cooling and air for valve gate operation. Locations for these connections are flexible, however based on experience the schematic indicates recommended positions.
AIR
AIR WATER
Cavity Numbering
Clear nozzle identification is necessary to ensure the hot runner properly interfaces with the mold, and that the nozzles are mapped correctly. The sequence illustrated to the right is recommended for simplicity.
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WATER
AIR
OPERATOR
TOP
Design Guidelines
Valve Gating Design Considerations
To ensure optimum gate quality, valve stems must respond quickly to the open/close signals. To avoid sluggish valve stem movement, the following should be considered prior to installation: Air supply should be clean and dry at a pressure between 550-830 kPa (80-120 psi). For thin wall parts and engineering resins the pressure should be between 100-120 psi. A four way solenoid valve is required to activate valve stems. Quick exhaust valves should be installed on both air lines to increase the speed at which the stems open and close. Quick air disconnects are not recommended since these can cause flow restrictions. Air plumbed direct from compressor. Minimize length of air lines. Use a Husky Air Kit for optimal performance.
Exhaust A Quick Exhaust Valve Solenoid Solenoid (Machine indicates when to actuate)
Gate Close
Gate Close
Line A Line B
Gate Open
Exhaust B
Gate Open
Gate Close
Line A Line B Exhaust B
Gate Open
Exhaust A Quick Exhaust Valve Solenoid Solenoid (Machine indicates when to actuate)
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Design Guidelines
Controller Interface
Voltage Supply To determine the correct manifold heater wattage, the available voltage supply must be specified. This practice is necessary since a significant wattage reduction can occur if the lower voltage is not compensated for. For a given heater the power output at 208V is only 75% of that at 240V. Voltage Supply 240 V 208 V Wattage 2,880 W 2,160 W
Amperage Limitations The amperage limit for each zone of the temperature controller needs to be identified. This ensures that the manifold heaters will not exceed the amperage limit. Electrical Connectors Electrical connectors are supplied with complete hot runner systems (optional for manifold systems). Refer to Electrical Connectors in the Accessories Section for installation information.
Connectors are available with either side or end clamps, and top or side entry, depending upon customer preference.
Side Clamp
End Clamp
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Design Guidelines
Husky Standard Electrical Connector Requirements Establishing an electrical wiring and connector standard will allow future interchangeability of hot runners and temperature controllers. The following Husky standards have been developed around typical controller capabilities for systems ranging from 2 to 16 drops. The departure from the standards may be required if space is not available or if the current requirements exceed the connectors limitations. 2-8 Drops For applications up to 8 drops, two 24 pin connectors are sufficient: one for power, and the other for thermocouples.
24 Pin (Power)
24 Pin (Thermocouple)
Standard connector pin mapping for both power and thermocouples is listed below. Pins for both connectors are rated to 16A. Pin Sprue Heater Manifold Zone #1 Manifold Zone #2 Tip #1 Tip #7 Tip #8 Spare 1 2 3 4 10 11 12 13 14 15 16 22 23 24
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Design Guidelines
2-8 Drop HR System Alternative (DME Standard) An alternative approach, is to employ one 25 pin connector for power and one 24 pin connector for thermocouples.
25 Pin (Power)
Standard connector pin mapping for 24 pin connectors shown on previous page. Standard connector pin mapping for 25 pin connectors.This connector is used for power. Pins are rated to 10A. Pin A1 A3 A5 A7 C5 C7 A9
Sprue Heater Manifold Zone #1 Manifold Zone #2 Tip #1 Tip #7 Tip #8 Spare
12-16 Drop HR System Applications between 12 to 16 drops use the following connector types.
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Design Guidelines
Figure 1-4: 12-16 Drop System Connector Configuration
6 Pin (Power)
32 Pin (Power)
Standard connector pin mapping for 6 pin connectors. Pins for zone control are rated to 30A. Pin Sprue Heater 1 2 Manifold Zone #1 3 4 Manifold Zone #2 5 6 Standard connector pin mapping for 16 pin connectors. This connector is used for controlling manifold thermocouples. Pins are rated to 16A. Pin Sprue Heater 1 9 Manifold Zone #1 2 10 Manifold Zone #2 3 11 Manifold Zone #3 4 12 Manifold Zone #4 5 13 Manifold Zone #5 6 14 Spare 7 15 Spare 8 16 Standard connector pin mapping for 32 pin connectors. This connector is used for nozzle power and thermocouples. Each connector can accommodate 16 nozzle zones. Pins are rated to 16A. Pin Tip #1 1 9 Tip #2 2 10 Tip #7 Tip #8 Tip #9 Tip #10 Tip #15 Tip #16 7 8 17 18 23 24 15 16 25 26 31 32
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Design Guidelines
Stack Hot Runner
Husky offers 2 level stack hot runners with Ultra 250, 350, 500, 750 and 1000 nozzles . A 2 level stack mold will nearly double the output per machine of a single face mold.Huskys experience gained in building over 2500 stack hot runners assures that all aspects of integrating the hot runner into the mold will be taken into account during design. In addition to 2 level stack systems there are also 3 level and 4 level systems available.
Moving Side Cavity Plate Stationary Side Cavity Plate
Machine Tie Bars
Sprue Bar Length Mold Opening Stroke
Hot Runner Mold Shut Height
Example of standard 2 level stack system
Standard Sprue Bar Standard sprue bars are solid sprue extensions that connect the hot runner with the machine nozzle.
Split Sprue Bar Split sprue bars allow free access to the molding surface without obstruction.
Back-to-Back Valve Gate Back-to-Back valve gates are available with standard and split sprue bars.
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Design Guidelines
Machine Requirements For Stack Mold Operation
In order to successfully run a stack mold; a molding machine must meet several criteria: Injection Unit The injection unit must be able to provide double the shot weight, plasticizing ability, and injection rate than would be required for a comparable single face mold. Sprue Break Capability (Standard Sprue Bar Only) The machine must feature sprue break capability. The injection unit of the machine must retract from the sprue bar to provide clearance to prevent collision and possible damage between the injection nozzle and sprue bar when the mold closes. Shut-off Nozzle (Standard Sprue Bar only) Upon sprue bar disengagement from the machine injection nozzle, a shut-off nozzle on the injection unit is necessary to prevent resin drooling. Shut Height Requirements Stack mold applications require approximately double the mold shut height and clamp stroke requirements relative to single face applications. Center Section Support The machine tie bars must provide accurate alignment of the hot runner during mold open and close. The machine specifications must be reviewed to ensure that the tie bars provide sufficient support and accurate repetitive alignment. Clamp (Standard Sprue Bar only) The clamp will require approximately 10t greater tonnage. This increased tonnage is necessary to oppose the force exerted by the machine nozzle on the movable platen which is usually opposed by the stationary platen.
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Design Guidelines
Thermal Gate Consideration
Ultra 250, Ultra 500, Ultra 750 and Ultra 1000 For all thermal gating methods, the nozzles can be positioned back to back.
Clamp Side
Injection
Leak Proof UltraSeal Technology
Back-toBack Nozzles Sprue Bar
Anti-Drool Bushing
Minimum Hot Tip Stack Hot Runner Shutheight Series Ultra 250 Ultra 350 Ultra 500 Ultra 750 Ultra 1000 2x2 to 2x4 128mm 5.04 in 125mm 4.92 in 130mm 5.12 in 131mm 5.16 in 132mm 5.20 in 2x6 to 2x24 148mm 5.83 in 136mm 5.35 in 130mm 5.12 in 131mm 5.16 in 147mm 5.79 in 2x32 to 2x48 208mm 8.19 in 208mm 8.19 in 210mm 8.27 in 211mm 8.31 in
NOTE:These values are based on one L-dimension and standard housing length, different L-dimensions, custom housing lengths and layout configurations can change these values
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Design Guidelines
Valve Gate Consideration
Ultra 350, Ultra 500, Ultra 750 and Ultra 1000 In order to accommodate customer requirements Ultra VG nozzles can be positioned offset or back to back. These designs provide ease of assembly and service access to the cylinders provided via air plates. Offset Valve Gate Back-to-back valve gate (B2B)
Minimum Offset Valve Gate Stack Hot Runner Shutheight Series Ultra 350 Ultra 500 Ultra 750 Ultra 1000 2x2 6.14 in 6.14 in 6.14 in 6.81 in 2x4 to 2x16 6.93 in 6.93 in 6.93 in 7.40 in
Minimum B2B Valve Gate Stack Hot Runner Shutheight Series Ultra 350 Ultra 500 Ultra 750 2x2 to 2x8 250mm 9.85 in 252mm 9.92 in 266mm 10.50 in 2x12 to 2x32 290mm 11.42 in 292mm 11.50 in 306mm 12.05 in
156mm 156mm 156mm 173mm
176mm 176mm 176mm 188mm
NOTE:These values are based on one L-dimension and standard housing length, different L-dimensions, custom housing lengths and layout configurations can change these values
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Design Guidelines
Standard Sprue Bar
The purpose of the sprue bar is to transfer the molten resin from the machine injection unit to the center section. When the mold is in the closed position, the machine nozzle seats against the sprue bar. When the mold opens the sprue bar moves with the center section and disengages from the machine nozzle.
Sprue Bar Guide
Husky calculates the correct sprue bar length based on the mold shut height and the required mold opening stroke. This ensures that the end of the sprue bar remains guided in the stationary platen when the mold is in the open position and that it will not contact the machine nozzle prematurely on mold close. The sprue bar is aligned to the machine nozzle by the sprue bar guide, which is installed behind the locating ring, or on the cavity plate. To prevent damage during operation, the sprue bar must not pull out of the sprue bar guide during the mold opening stroke.
Anti-Drool Bushing
The function of the anti-drool bushing is to minimize the amount of resin that drools out of the sprue bar when it is not in contact with the machine nozzle. As the sprue bar moves with the center section during mold open, the residual melt pressure in the manifold forces the anti-drool bushing backward Residual Pressure
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Design Guidelines
Offset Sprue Bar
When the sprue bar can not be positioned at the mold centerline, an offset sprue bar can be used. Using an offset sprue bar requires additional mold shut height to accommodate the transfer manifold attached to the stationary platen. The sprue bar can be positioned at any side of the mold.
Transfer Manifold
Heat Shield
Offset Sprue Bar
Sprue Nozzle
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Design Guidelines
Standard Sprue Bar Installations
Standard Small Sprue Bar Small Sprue bar compatible with the following systems: - Ultra 250 HT stack - Ultra 350 HT stack, Offset VG stack, B2B VG stack - Ultra 500 HT stack, Offset VG stack, B2B VG stack - Ultra 750 HT stack, Offset VG stack, B2B VG stack - Ultra 1000 HT stack, Offset VG stack, B2B VG stack Heat Shield Installation Plate A
35.0 [1.38]
2x R 0.8 [.03]
4x FULL R
38.0 [1.50]
47.6 [1.87] 73.0 [2.87]
Heat Shield Installation Plate A

2x R 0.8 [.03] 2x 20.0 [.79]
2x 14.0 [.55]
35.0 [1.38]
Sprue Bar Thru Hole Installation in Core Plates

2x R 17.5 [.69]
Locating Installation Ring

140.0 R 0.8 [.03] 69.85 + 0.03 0 2.750 + .001 - .000 +0.02 0 5.51 +.008 - .000
R 0.8 [.03]
110.0 [4.33]
90.0 [3.54]
38.0 [1.50]
73.0 [2.87]
2x 25.4 [1.00]
38.0 [1.50]
2x 14.0 [.55]
38.0 [1.50]
6.0 [.24]
19.0
0 - 0.03
+ .000 .75 - .001
35 0 [1 38]
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x 19.0 [.75]
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Design Guidelines
Standard Medium Sprue Bar Medium Sprue bar compatible with the following systems: - Ultra 250 HT stack - Ultra 350 HT stack, Offset VG stack, B2B VG stack - Ultra 500 HT stack, Offset VG stack, B2B VG stack - Ultra 750 HT stack, Offset VG stack, B2B VG stack - Ultra 1000 HT stack, Offset VG stack, B2B VG stack Heat Shield Installation Plate A
50.0 [1.97]
2x R 0.8 [.03]
4x FULL R
62.8 [2.47] 88.2 [3.47]

2x R 0.8 [.03] 2x 20.0 [.79]
2x 14.0 [.55]
120.0 [4.72]
2x 25.4 [1.00]
50.0 [1.97]
100.0 [3.94]
2x R 14.0 [.55]
100.0 [3.94]
50.0 [1.97]

2x R 25.0 [.98]

140.0 + 0.20 0 5.51 + .008 - .000 2x MB
R 0.8 [.03]
+ 0.03 100.0 0
+ .001 3.94 - .000
R 0.8 [.03]
140.0 [5.51]
50.0 [1.97]
6.0 [.24]
50.0 [1.97]
19.0
0 - 0.03
.75
+ .000 - .001
50.0 [1.97]
2x 25.0 [.98]
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Design Guidelines
Standard Large Sprue Bar Large Sprue bar compatible with the following systems: - Ultra 250 HT stack - Ultra 350 HT stack, Offset VG stack, B2B VG stack - Ultra 500 HT stack, Offset VG stack, B2B VG stack - Ultra 750 HT stack, Offset VG stack, B2B VG stack - Ultra 1000 HT stack, Offset VG stack, B2B VG stack Heat Shield Installation Plate A
60.0 [2.36] 2x R 0.8 [.03]
4x FULL R
105.0 [4.13]
70.6 [2.78] 96.0 [3.78]

2x R 0.8 [.03] 2x 20.0 [.79]
2x 14.0 [.55]
105.0 [4.13]
2x 25.4 [1.00]
60.0 [2.36]

2x R 30.0 [1.18]

140.0 108.0 R 0.8 [.03] + .008 + 0.20 5.51 - .000 0 +.001 + 0.03 4.25 - .000 - 0
138.0 [5.43]
118.0 [4.65]
45.0 [1.77]
45.0 [1.77]
2x 14.0 [.55]
2x M8
45.0 [1.77]
R 0.8 [.03]
6.0 [.24] 0 + .000 .94 -0.03 - .001
24.0
60.0 [2.36]
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2x 22.5 [.89]
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Design Guidelines
Split Sprue Bar
The Split Sprue Bar (SSB) transfers resin from the machine injection nozzle to the hot runner of a stack mold. The transfer is designed to free the parting line from component interference while preventing resin leakage. The SSB accomplishes this through the connection of two independently controlled assemblies enclosed within the mold. These assemblies interface with each other at the parting line during mold closed and disengage upon mold open. This makes free drop of parts possible and allows unrestricted robot access for part take-off. There are two SSB configurations: Inline and Offset. Located in the center of the mold, the Inline version is mounted co-axially with the machine nozzle. Resin flows though the inline valve gate unit mounted in the core backing plate and transfers melt to the moving side split sprue bar assembly through the tip interface at the parting line. The Offset SSB employs a transfer manifold system mounted to the stationary platen to route flow from the injection nozzle to a SSB unit located at a place of convenience to the mold design.
Key Features: Taper stem shut-off Radial taper at nozzle lead-in for alinement
Patented sliding joint Sliding joint with spring packs for robustness
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Design Guidelines
Two standard throughput options are available, Medium and Large. Huskys Application Engineering personnel can assist in the selection of the proper throughput option for your system. The Large SSB is available in an Offset configuration only. Inline Offset
The SSB is located on the center line of the mold and is directly fed by the machine nozzle
An Offset system allows the SSB unit to be positioned freely in the mold frame. A transfer manifold routes the feed from the machine nozzle to the SSB unit location.
204mm [8.0]
73mm [2.87]
Hole through mold plates
138mm [5.44]
Hole through platen
127.4mm [5.0]
Minimum Shutheight: - Medium SSB: 200mm [7.87"] - Large SSB: 216mm [8.50"]
Example: Medium size Split Sprue Bar
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Design Guidelines
UltraSync
Synchronized stem actuation - Better shot to shot consistency - Precise repeatability Tight pitch spacing - Minimum 18mm drop to drop pitch spacing when used with the Ultra 350 Clean room compatibility - Electric Consistent LX stem force
Stem easily accessibility in the machine

Multiple nozzle sizes - Ultra 350, Ultra 500, Ultra 750 - Available for VG or VX tip configuration Two actuation options - Servo motor (electric) - Hydraulic Please contact Husky for further information
22.3 [0.878]
18.0 [0.709]
25.4 [1.00]
44.5 [1.75]
25.4 [1.00]
44.5 [1.75]
18.0 [0.709]
22.3 [0.878]
R 31.5 [1.242]
R 32 [1.26]
R 40.4 [1.60]
Ultra 350 Pitch Spacing
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Design Guidelines
Center Section Support Types
The center section of a stack mold is supported by the tie bars of the injection molding machine using one of three methods. Horizontal Support Vertical Support Machine Mounted Carrier
For all three methods, it is essential that the machine be level to avoid unnecessary wear on the mold and machine components caused by misalignment. Horizontal Support The horizontal support approach uses an H-shaped sled that rides on the lower machine tie bars to support the hot runner. The upper machine tie bars are used to guide the sled during normal operation. The wide stance of the horizontal support enables the weight of the hot runner to be evenly distributed along a wide section of the machine tie bars. A horizontal support is used when the mold is wider than the machine tie bar spacing. For safety reasons the mold must be at least as wide as the center to center tie bar spacing. The mold must also have a minimum of 70,0mm (2.76") and a maximum of 120,0mm (4.72") clearance over the lower tie bars and a minimum of 30,0mm (1.18") clearance beneath the upper tie bars. Two options exist for controlling hot runner movement: Rack and Pinion Gear Mechanism Harmonic Linkage Mechanism (available only with Husky machines)
>210,0 (8.27")
>30,0 (1.18") Clearance
>70,0 (2.76") Clearance <120,0 (4.72") Clearance Mold Edges Must Be Wider Than Tie Bars Inside Spacing
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Design Guidelines
Vertical Support The vertical support uses an hourglass shaped outrider that is fastened to the operator and non-operator sides of the center section. The weight of the hot runner is evenly distributed over a wide area of the lower machine tie bars by half shoes. The mold must be between 10,0mm (0.39") and 85,0mm (3.35") narrower than the horizontal tie bar spacing. The upper tie bars provide guidance and stability to the center section during operation. A rack and pinion gear mechanism provides center section movement.
Drop Limiters Mold Support
Tie Bar Spacing >420,0 (16.54") <920,0 (36.22")
Mold to Tie Bar Spacing <10,0 (0.39") >85,0 (3.35")
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Design Guidelines
Controlled Center Section Movement
Controlled movement of the center section is critical to ensure that as the mold opens, the hot runner always remains centered between the clamp and injection sides of the mold. The recommended methods of controlling center section movement include: Rack and Pinion Mechanism (Single and Multiple Gear) Harmonic Linkage Mechanism (available only with Husky machines)
The method employed for a given application is customer specified. Each method is examined in greater detail in the sections that follow. Rack and Pinion Mechanism With the rack and pinion single gear mechanism, two racks are employed per mold side. The top rack is fastened to the clamp side while the bottom rack is fastened to the injection side. Design Considerations: Machine stroke must be 25,0 mm (0.98") less than the mold shut height to ensure that rack engagement is maintained.
Rack Mounting to Mold
230,0mm (9.06") Keep the Surface of this Area Clear of all Mold Components to Avoid Interference with Racks
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Design Guidelines
Harmonic Linkage The Harmonic Linkage mechanism is only available for use in a Husky machine. With the harmonic linkage mechanism, a propeller and harmonic arm mechanism is fastened to the center section. The harmonic linkage mechanism is used for molds that have a short ejection stroke and a machine stroke less than 305mm (12.01"). Keep Sides of Mold Clear of all Components to Avoid Interference with Harmonic Linkage Movement
Harmonic Arms
Propeller
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Vertical Tie Bar Spacing
Plate Length
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Horizontal Tiebar Spacing Customer Specified Electrical Connector Type Machine Type Tiebar Diameter Guide Pin X & Y Location Type & Diameter Latch Tap Latch Tap Clamp Slot X & Y Location (Width, Length, Depth) Customer Mold Interface Tap X & Y Location Customer Mold Drop Number X & Y Location Customer Features Critical Dimensions Needed: ie. Depth, Width, Length, Diameter Customer Specified LDimension Distance from Clamp Face of Manifold Plate to Mold Surface
Design Guidelines
Customer Drawing Requirements (Hot Runner Systems)
Before Husky can begin engineering, the hot runner interfacing features indicated in the figure below must be defined by the customer when submitting the Mold Layout drawings along with the Design Information Form.
Contact Husky if you have any questions when completing the Mold Layout Sheets or the Design Information Form.
237 OPERATOR SIDE

Customer Features X & Y Location Plate Width Customer Specified Water Fittings Type & Location Maximum Hot Runner Thickness
Customer Mold Interface Taps (Specify Thread, Depth, Quantity) Guide Pin Protrusion Measured from Clamp Face of Manifold Plate
Design Guidelines
Customer Drawing Requirements (Manifold Systems)
Before Husky can begin engineering, the customer features indicated in the figure below must be defined by the customer when submitting the Mold Layout drawings along with the Design Information Form. Contact Husky if you have any questions when completing the Mold Layout Sheets or the Design Information Form.
Customer Specified L-Dimension Distance from Clamp Face of Manifold Plate to Mold Surface Customer Specified Electrical Connector Type Customer Mold Drop Number X & Y Location
OPERATOR SIDE
TOP
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Plate Width Plate Length

Design Guidelines

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Design Guidelines

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Design Guidelines

Design Guidelines Cavity Design

Nozzle Seal Off Diameter

Plate Bolt (see chart following page)

Backing Plate Cooling

Manifold Plate Cooling

Line A Line B Exhaust B

Machine Tie Bars

Sprue Bar Length Mold Opening Stroke

Hot Runner Mold Shut Height

Example of standard 2 level stack system

Leak Proof UltraSeal Technology

Back-toBack Nozzles Sprue Bar

156mm 156mm 156mm 173mm

176mm 176mm 176mm 188mm

Sprue Bar Guide

Offset Sprue Bar

47.6 [1.87] 73.0 [2.87]

Heat Shield Installation Plate A

Sprue Bar Thru Hole Installation in Core Plates

Locating Installation Ring

+ .000 .75 - .001

62.8 [2.47] 88.2 [3.47]

Heat Shield Installation Plate A

Sprue Bar Thru Hole Installation in Core Plates

Locating Installation Ring

+ .001 3.94 - .000

70.6 [2.78] 96.0 [3.78]

Heat Shield Installation Plate A

Sprue Bar Thru Hole Installation in Core Plates

Locating Installation Ring

6.0 [.24] 0 + .000 .94 -0.03 - .001

Example: Medium size Split Sprue Bar

Stem easily accessibility in the machine

Ultra 350 Pitch Spacing

Ultra 500 Pitch Spacing

Ultra 750 Pitch Spacing

>30,0 (1.18") Clearance

Drop Limiters Mold Support

Tie Bar Spacing >420,0 (16.54") <920,0 (36.22")

Mold to Tie Bar Spacing <10,0 (0.39") >85,0 (3.35")

Rack Mounting to Mold

Vertical Tie Bar Spacing

Customer Drawing Requirements (Hot Runner Systems)

237 OPERATOR SIDE

Plate Width Plate Length

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