Hot Runner-Nozzle Heater

[Sammy101]

Rick,

Yes. I mistakenly accounted the friction to flow restriction.
By the way, this is another issue, but we observed in most cases, that our product under this mold (and heater) frequently experiencing voids on the product, especially near the gate or where the tip is located.
Do you believe this has something to do with the flow restriction or our issues with the tip or heater problem?

Sammy.

[Jendalf]

Any pictures? Voids can appear due high temperature but how does they look like?

J

[rickbatey]

Sammy I think that the high heats are causing the voids due to the heat or poor melt flow into the cavity. When you guys find the root cause and correct it, I think some folks will sleeping well for the first time in a long time.
Rick

[Sammy101]

Rick,

We are also looking forward for the resolution of the problem and at last, you are correct, we can take some nap time.
I will take your advises.

Sammy

[Sammy101]

Dear Rick and Jendalf,

After I checked the condition of the mold and runner I found that it has no shut-off valve and just a free flow system. I attached the picture for reference.
Now, looking at the condition of the nozzle, which is an obsolete version of INCOE, I think the design is not as efficient as the latest design which leaves the opportunity to the heater to extend more heating to compensate the heat loss on the material. Though the outer cap of the nozzle assy is quite thick, still the heat loss due to contact with the colder plate is still bearing on the heater.
In addition to the concern, I found our that the this type of heater has a built-in thermocouple making it prone to frequent replacement if either the heater or the thermocouple is not working.

I will attach the hot runner assy in the next page since I think our page has a limit for the attachment.

Your insight with this findings is highly appreaciated and valued.

Sammy

Attachment 109
Attachment 108

[Sammy101]

Rick and Jendalf,

Here is the after image when we open the hot runner system.

Sammy.

[rickbatey]

Sammy- I wonder about the rust on the manifold because that's alarming for such a simple system. Lastly I hate that so many of the drops stuck in the mold base when the manifold was pulled. I would also expect a manifold that small to pull by hand w/o lifting eyes. Check the mold base for leaking plugs, water circuits, around the manifold. I bet there are some dripping water onto the manifold; at least that would explain heat settings and rust.
Rick.

[Sammy101]

Rick,

I will take that into consideration.
By the way, what do you thick of my findings with the condition of the heater system? I know it too outdated and perhaps the cause of too much heat-loose which forces the nozzle heater to work more?

Sammy

[Sammy101]

Jendalf,

It is unfortunate that I do not have the picture now but the void is inside the plastic. Now the concern is, that the product is a case that we place acid, then later due to unwanted voids, the acid leaks later at the gate or the area near the gate.

Sammy