Barrel Heaters - Hasmak.com.tr

W A T L O WHot RunnerNozzle <strong>Heaters</strong>Case HistoryHot Runner Nozzle <strong>Heaters</strong>Problem:An injection molding customerrequired a more efficient heatingmethod for their hot runner systemto increase start-up and throughput.A segment where hot runnersystems have been readily adoptedis in the production of plasticpreform parts (unblown bottles).This particular molder was utilizingmultiple plastic resins with melttemperature ranges of 176°C to301°C (350°F to 575°F). Thick filmtechnology heaters have anoperating range up to 500°C (932°F)and due to the overall efficiency andlow profile; they were an idealheating method for this hot runnersystem.The heated nozzle section of this hotrunner system utilized cable heatersto keep the melt at temperature. Thecustomer found that the loose fittingwound heater design was notproviding an even thermal profile onthe nozzle resulting in lostefficiencies. Therefore, a differentapproach was required.Solution:Multi-zone distributed wattage thickfilm nozzle heaters from Watlow.The thick film heating technologyoffered the OEM multiple benefits tomeet the needs of the application.Watlow’s thick film nozzle heatersprovide OEMs and molders withthe following advantages:Low radial ink / substrate profile –0.9 mm (0.035 in.)• Allows for higher nozzle density inthe tool.• Allows for use of larger nozzleswith larger feed into a smaller holeresulting in more plasticthroughput.• Permits water jackets to be closerto the nozzle; better controlresulting in higher part yield.Construction• Provides uniform surface contactalong the nozzle- even thermalprofile• Increased controllability of thesystem; thermocouples areseparate from the heater andimmersed into the body of thenozzle, resulting in a moreconsistent process temperaturereading• Flexible leads allow for greatermanipulation in wiring channel,which provides greater manifolddesign flexibility• Moisture and contaminationresistant• High-temperature moldedterminationPrecise wattage distribution andtight tolerance• Reduces part scrap• Provides more consistent resultsthan traditional methods• Able to maintain consistenttemperatures as the system isrunningPositive resistance coefficient• Improves response time,controllability and heater life• Faster ramp to operatingtemperatureOverall Results:The customer experienced benefitsof cost savings on steel, additionalmachining; purchasing one heater(manifold) versus multiple tubulars,decreased overall powerconsumption, faster systemresponse and a higher part yield.This customer has plans to orderadditional thick film technologyheaters to incorporate into additionalsystems.Thick film nozzle heatersprovide a superior temperatureuniformity capability by putting theenergy exactly where it is needed bythe application.Injection MoldingHot Runner Nozzle <strong>Heaters</strong>139