hot sprue bushings · pdf file2 rev. 05/97 hot sprue bushings d-m-e hot sprue bushings...

Rev. 05/972

Hot Sprue Bushings

D-M-E Hot Sprue Bushings

ContentsPage

Hot Sprue Bushings ............................................................................ 3

Straight Shot ....................................................................................... 04 - 07

Gate Mate ........................................................................................... 08 - 12

High Performance Nozzles ................................................................. 13 - 15

Thermag ............................................................................................. 16 - 17

Multiple Gate Nozzle........................................................................... 18 - 19

Àutonozzles ........................................................................................ 20 - 22

Osco® Single Valve Gate Nozzles ...................................................... 23 - 25

Micro Single Bushings ........................................................................ 26 - 28

Process Data Sheet ............................................................................ 29 - 32

Case Studies ...................................................................................... 33 0

● to eliminate conventional cold sprues● to permit larger shots and fill faster● to improve the performance of all plastic

materials by allowing direct gating in opti-mum conditions

Positive temperature control with J-type thermocouplesand D-M-E Smart Series® (G-type) controllers.

Reduced cycle times due to more positive cooling.

Faster start-ups provided by positive temperature controlof the gate area.

Proven performance and reliability based on years ofexperience.

Easy installation and operation.

BenefitsDirect part gating eliminates the need to trim sprues andleaves no witness marks on the molded part.

Improved part quality due to a shorter injection path.

Minimal gate vestige resulting in better part appearance.

Unique range of sizes to cope with both large and smallmoldings.

Vast choice of design to enable proper gate selection.

Advanced-design square coil heaters or high power,sturdy cast-in heaters, both give an outstanding thermalprofile and long life.

The best solution...

D-M-E EUROPE • Industriepark Noord I • B-2800 Mechelen • Tel. +int. 32.15 / 21 50 11 • Fax +int. 32.15 / 21 82 35

Molding Systems

Hot Sprue Bushings

• Straight Shot• Gate Mate• High Performance nozzle• Thermag• Multiple Gate Nozzle• Autonozzle• Osco® Single

Valve Gate nozzle• Micro Single Bushing• Process Data Sheets

Rev. 05/97

Hot Sprue Bushings

3D-M-E Hot Sprue Bushings

Depending on the application, a suitable bushing can be selected from one of the following D-M-E Hot Sprue Bushings :

Diversity

Straight Shot

Featuring an unrestrictedstraight melt channel made ofwear resistant, hardenedsteel, the Straight Shot isoften used for commoditymaterials. The Pico and theExtended Pico Straight Shotare provided with a highperformance cast-in heaterand are used successfullywith engineering materialsrequiring a tight temperaturecontrol, like PC, POM, PA,PETP, etc.Gating is of the sprue type.

Gate Mate

The vast Gate Mate familyfeatures a melt channel withhigh heat conductivity,allowing larger shots withminimal gate vestige due to itspoint gate tip. A wide varietyof melt channels and tips isavailable in variousgeometries. The tips aremade from either nickel platedberyllium copper or a uniquehigh wear resistant materialcombining extreme hardnesswith high thermal conductivity.Gate configurations other thanthe point tip are also available,e.g. the thru hole tip whicheliminates potential flow lines.

Thermag

The Thermag is an all steelbushing designed for directpart gating, especiallyqualified for bulk materials,like PP, PS, PE.

High performance Nozzles

The CIA High PerformanceNozzles with cast-in heaters,developed exclusively forD-M-E, can be used for allapplications, especiallyengineering grade resins witha high degree of crystalinity.In combination with a bandheater they are also suitablefor direct part gating in singlecavity molds. The HighPerformance Nozzles aredelivered with a seal ring. Theradius has to be made by thecustomer.

Multiple gate nozzles

The Multiple gate nozzle is suitablefor multiple gating of small parts inmultiple cavity molds or larger partsin single cavity molds. Providing upto 6 points of sprueless injection,located on a small circle, this selfcontained round manifold with Hot-One type probe gating offersoptimum gate cosmetics. Two gateconfigurations: point gate and thruhole whereas the point gate type isalso available in a wear resistantversion for abrasive materials.Each gate is fed through a microHot-One nozzle with its uniquethermal heat. To obtain a betterinsulation titanium support andspacer rings are used.

Autonozzles

For direct gating of large and/or deep plastic parts. Anylength available between 200and 800 mm. Two standardtips are available: point gateand thru hole type. Suitablefor all unfilled plasticmaterials. Maximum shotcapacity 10.000 cm3/sec(depending on material, partgeometry and flow condition).

Micro single bushings

D-M-E's Micro single bushingprovides a solution for direct gatingwhere space is limited. Near thegate, if fits in a boring of 17 mmdiameter only. It features anexcellent melt temperature controlwith two independent zonespossible. The design of the cast-inheater at the gate end is unique,reduces heat losses tremendouslyand guarantees temperatureuniformity. Two gates are possible:point gate and thru hole type. Thepoint gate is supplied in a standardand a wear resistant version. Mostkind of engineering plastics havebeen successfully injected with theD-M-E Micro single bushing.

Osco® single valve gate nozzles

D-M-E Osco's single valve gatenozzles, full body type andbodyless type, are designed toprovide more flexibility and betterresults in any molding application.With an externally mountedcylinder it is the most trouble freeand easy to install systemavailable. The single valve gateoffers a unique external pinadjustment to simplify machiningand mold assembly requirements.Also a replaceable pin sealeliminates leaks and the originalpin guide eliminates gate wear.The system's shaft-driven 1:1 ratioprovides longer components lifeand safer operation

Rev. 05/97

Straight Shots - SSBU

Cast-in heaters forthe ultimate heat profile

The entire heater of the Pico and Extended PicoStraight Shot is encapsulated in copper and iscovered with a stainless steel sheath for insulationand protection. Copper is used to give a betterheat transfer.

Distributed wattage allows heat to be preciselyplaced for even temperature control. The heatercasing gives exact heat and provides the ultimateheat profile.The internally grounded thermocouple location waschosen for optimum heat monitoring and control.


Benefits

The Straight Shot was designed to remove thesuperfluous direct gate on single moldings.The melt is guided through a straight centralchannel and without deflection directly to thecavity.

The channel is made of hardened steel and iswear resistant. An optimal heat separation isprovided by the minimum contact surface betweenthe bushing and the mold.

Heaters with integrated thermocouple guarantee auniform temperature along the flow channel. Thusa thermal overstressing of the plastics melt isimpossible.

Further advantages of the Straight Shots are thesmall dimensions, easy modification of the gateopening and a variety of four types: Standard,Mini, Pico, and Extended Pico Straight Shot.

The Standard and Mini types use optimized squarecoil heaters, the Pico and Extended Pico StraightShot are provided with a copper cast-in heater.

The best solution...● to eliminate conventional cold sprues● to improve part quality● to reduce cycle time● to reduce shear, stress

and pressure loss● to improve performance● to increase productivity● to save energy

● for large shots● for difficult materials● for materials savings● for shot capacities up to 1000 gr.● for a low cost per gate● for a uniform temperature profile

Thermocouple

EngineeredDistributed Wattage

Copper cast-inConstruction

StainlessSteelCasing

Rev. 05/97

6 max

3 m

ax

REF A RSSBU-7536-N 36 0

SSBU-7556-N 56 0

SSBU-7576-N 76 0

SSBU-7596-N 96 0

SSBU-8536-N 36 15

SSBU-8556-N 56 15

SSBU-8576-N 76 15

SSBU-8596-N 96 15

33.5

41.5

131

ø 2

3

ø 3

2.8

A

5.2

ø1.

5

ø 1

2

ø 4

0

18

90°

8

4

ø 6

R0/15

41.5

75.5

8

18

Ø 1

.5

Ø 2

3

Ø 1

2

Ø 3

2.8

33.5

4.5

A

Ø 4

0Ø 6

R0/15

90°

4


5

GatingThe D-M-E Straight Shot is designed for direct partgating or feeding runner profiles. It is supplied with a 1.5mm gate opening.In case the gate opening is insufficient, the diameter canbe enlarged. Thereby the front side of the bushing isreduced, fig. 1, detail X. Body and sprue bushing shouldbe reduced by the same length.The cost per gate is at its lowest because some gatevestige is admitted and also a circular mark is accepted.The Straight Shot can be exchanged for already installed,conventional sprue bushings on almost any injectionmold.Changing color is no problem.

Extended Pico Straight Shot

Gate opening modification

D-M-E Hot Sprue Bushings

Standard Straight Shot

Pico Straight Shot

REF A RSSBU-1340-2-N 81.5 0

SSBU-1340-R-2-N 81.5 15

Gate opening Length to cut off

Ø 2 0.25 mm

Ø 2.5 0.50 mm

Ø 3 0.75 mm

Ø 3.5 1 mm

Ø 4 1.25 mm

Ø 4.5 1.50 mm

Ø 5 1.75 mm max.

Leng

th to

cut

off

1.5

Ø 6

Ø 12

fig. 1

Detail X

ø 2

3.6

8

R 0

/15

6

17

ø 5

0

4

131ø

25

ø 1

.5

A 116 - A

90°

ø 4

9.6

ø 6

8

ø23

.6 R 0

/15

6

75.5

17

ø 5

0

4

ø 2

5

ø 1

.5

A 34.3

90°

ø 4

9.6

ø 6

Types

REF A RSSBU-7640-2-N 26 0

SSBU-7640-R-2-N 26 15

REF A RSSBU-8026-2-N 26 0

SSBU-8026-R-2-N 26 15

Countersunk gating Concave gating Runner gating

Mini Straight Shot

Rev. 05/97

X1211

ø 28

ø 50

ø 90

ø 54 m

ax4

3A

5

ø 25

H9

H7

H7

±0,5

7 x 45°

X

R3

12

ø 32.8

ø 37

ø 26

3

5

33A

max

3

ø 12

ø 90

ø 44

H9

±0.5

H7

H7



Installation InstructionsStandard - Mini

Spare PartsExtended

PicoPicoMiniStandard

REF REF REF REFBodyStandard & Mini

A

SSB-36-N 36SSB-56-N 56SSB-76-N 76SSB-96-N 96

SSB-7640-N

SSB-8026-N

SSB-7640-N

Square coil heaterTC type J

Cast-in heaterTC type J

WRPK-42/90240 V/280 W

WRPS-32/90230 V/400W

WRPS-42/90230 V/300 W

WRPK-32/90240 V/280 W

Sprue bushing R

SSS-75-N 0SSS-85-N 15

R

SSS-8026-N 0SSS-8026 -R-N 15

R

SSS-7640-N 0SSS-7640 -R-N 15

R

SSS-1340-N 0SSS-1340 -R-N 15

M6 x 10

M6 x 10

M4 x 8

M4 x 8

Screw

Special usesFor any non-reinforced bulk plastics like PE, PP, PS,ABS, SAN etc., use the Standard or Mini StraightShot.

For non-reinforced and reinforced technicalthermoplastics with a tight processing zone, like PA,POM, PC, PETP etc., select the Pico or ExtendedPico Straight Shot.

Pico - Extended Pico

Standard MiniA X A X

36 113 26 57,556 11376 11396 113

Pico Extended PicoA X A X26 57,5 81,5 113

Pico &Extended Pico

50-52 HRC

A

Rev. 05/97

L

REF R A

SSBT-4507ER-2 22,2

SSBT-4513ER-2 34,9

SSBT-4517ER-2 47,6

SSBT-4523ER-2 12,7 60,3

SSBT-4527ER-2 73,0

SSBT-4533ER-2 85,7

SSBT-4537ER-2 98,4

SSBT-6507ER-2 22,2

SSBT-6513ER-2 34,9

SSBT-6517ER-2 47,6

SSBT-6523ER-2 19,05 60,3

SSBT-6527ER-2 73,0

SSBT-6533ER-2 85,7

SSBT-6537ER-2 98,4

REF R A

SSBT-4507E-2 22,2

SSBT-4513E-2 34,9

SSBT-4517E-2 47,6

SSBT-4523E-2 12,7 60,3

SSBT-4527E-2 73,0

SSBT-4533E-2 85,7

SSBT-4537E-2 98,4

SSBT-6507E-2 22,2

SSBT-6513E-2 34,9

SSBT-6517E-2 47,6

SSBT-6523E-2 19,05 60,3

SSBT-6527E-2 73,0

SSBT-6533E-2 85,7

SSBT-6537E-2 98,4

Straight Shots - SSBT


Installation Instructions

GatingS-Series E-Series

E-Series E-Series ER-Series

ER-Series ER-Series E & ER-Series mustalways be altered,shortened asshown.

REF. Volts Watts L Leads at

SSTC-32 5°

SSTC-32-90240 300 117,5

90°

5

1211

ø 25.4

ø 50.67

ø 28

3A

max

4

ø 90

ø 54

20

H7

H7

H9

±0,5

7 x 45°

Ø 4.06Max 6.81

1.5 to 2

Min 6.35

2.30/3.00

Max 6.81

Gate Dia

Max 6.81

Gate Dia

Max 6.81 6.35

6.356.35

REF R A

SSBT-4507-2 22,2

SSBT-4513-2 34,9

SSBT-4517-2 47,6

SSBT-4523-2 12,7 60,3

SSBT-4527-2 73,0

SSBT-4533-2 85,7

SSBT-4537-2 98,4

SSBT-6507-2 22,2

SSBT-6513-2 34,9

SSBT-6517-2 47,6

SSBT-6523-2 19,05 60,3

SSBT-6527-2 73,0

SSBT-6533-2 85,7

SSBT-6537-2 98,4

Types

5°90°

ø 50.67

ø 1

014

.17

A

129.

29

ø 25.40ø 4.06

R12.7ø 49

ø7.87

g6

90° 5°

ø 25.4

ø 1.52

ø50.67

ø 1

0

14.1

7

R12.7ø 49

ø 7.87

135.

64

A

g6

A

135.

64

ø 25.4

ø 3.05

9°

ø 50.67

90° 5°

14.1

7ø

10

R12.7ø 49

ø 7.87

Spare Parts

S-Series

E-Series

ER-Series

E-Series

Rev. 05/978D-M-E Hot Sprue Bushings

Gate Mates - GM

● for excellent color andmaterial changes, due toan unobstructed melt flow

● for an optimal heat distribution

● for engineering plastics● for thousands of trouble-free applications

BenefitsThe Gate Mate incorporates a high thermal conductivitycentral melt channel in a steel housing or body.The melt channel is made of nickel-plated copper-beryllium for general use, or of conductive high wearresistant material for plastics with abrasive fillers. Themelt channels or tips can be replaced and one steel bodycan accept various tip styles. This design allowsconsiderable flexibility. Many different tip and bodycombinations are available.

The fitting surfaces of the bushing in the mold representan optimal trade-off between mechanical strength andheat losses. Due to the particular shape of the head,heat losses are limited. From near the gate to well insidethe body, an insulating layer of plastic materialguarantees a uniform temperature up to the gate.Independent thermocouples are strategically located andeasy to replace.

D-M-E’s new cast-in heaters can also be fitted on theGate Mate. Combined with the hard wear tip, the GateMate family represents a big step ahead in technology.They are easily installed in new and existing molds.

Special usesWith its full length beryllium copper tip, the Gate Matehas been extensively used on most materials exceptglass filled resins. The insulated tip can be positionedinto the gate with a minimal mark on the molding.

If the injected plastic is particularly prone to weld lines,then the usual point gate tip can be replaced by the thru-hole tip. Glass filled or other abrasive materials can behandled by the hard wear resistant tip with its exceptionalcombination of hardness and thermal conductivity.


● to improve partquality

● to obtain a minimalgate mark on themolded part

● to prevent direct contact betweenthe nozzle and the moldedcomponent

● to reduce cycle time

● to reduce part stress

● to create more space for cooling

Rev. 05/97 9D-M-E Hot Sprue Bushings

Gate Mates - GM

Types

Ø a

19 40

A A’ L L’

40 39,8 64,5 64,3

Ø a

22 60

22 85

A A’ L L’

59,5 59,3 87,5 87,3

84,5 84,3 112,5 112,3

Compact

Standard

SUB-ASSEMBLY consisting of :

Body Heater TC

REF. Flat Radius Square Cast-in Thermo-Sub-Assembly coil heater couple

heater

Ø a

GMC-1940 ◆ SCH-1940 TC-19

GMD-1940 ◆ SCH-1940 TC-19

GME-1940 ◆ CIH-1940

GMF-1940 ◆ CIH-1940

R0/15.5

Ø 1

9

Ø 4

0

Ø 4

8

L ( L' )

A ( A' ) 15.5

A

Ø

A

Ø

R 15.5

A A’ L L’

59,5 59,3 87,5 87,3

84,5 84,3 112,5 112,3

Ø a

19 60

19 85

R 0/ R15.5

Ø 1

9

Ø 5

4.5

Ø 4

8

15.5A ( A' )

L ( L' )

Jumbo

Ø 5

7.5

Ø 5

1R0/15.5

Ø 2

2

15.5A ( A' )

L ( L' )

GMC-1960 ◆ SCH-1960 TC-19

GMD-1960 ◆ SCH-1960 TC-19

GME-1960 ◆ CIH-1960

GMF-1960 ◆ CIH-1960

GMC-1985 ◆ SCH-1985 TC-19

GMD-1985 ◆ SCH-1985 TC-19

GME-1985 ◆ CIH-1985

GMF-1985 ◆ CIH-1985

GMC-2260 ◆ SCH-2260 TC-19

GMD-2260 ◆ SCH-2260 TC-19

GME-2260 ◆ CIH-2260

GMF-2260 ◆ CIH-2260

GMC-2285 ◆ SCH-2285 TC-19

GMD-2285 ◆ SCH-2285 TC-19

GME-2285 ◆ CIH-2285

GMF-2285 ◆ CIH-2285

How to orderTo order a complete Gate Mate :1. Select the required body and heater type which results in

finding the correct sub-assembly reference number (REF.)2. Select one of the four available tips (see page 10) and state

the reference number (REF.)3. Both reference numbers (REF.) as listed under point 1. and

2. are required to get the right delivery.Note: - Dim. a = Nominal value of A or A’

- Dim. A’ & L’ : for thru-hole tip - type O (= + 0,5 mm)

Rev. 05/97

*F for S, H and B = A + A*F for O, add 0,5 mm A = K x A x t x 10-6

K 12,5 for type S, O, BK 11,5 for type H t = t° max - t°mold

H9

H7

ø G

ø10

h

k

3

2

15.5

m*F =

( A

+

A)

ø B

ø 90

ø D

ø C

ø E

ø d

H7

+0

-0.1

+2 -0

+0.

2-0

8 min


Gate Mates - GM

Installation InstructionsTipsFor Compact, Standard, Jumbo

Standard tip - Type S

REF. d

JTS-1940 6

JTS-1960 6

JTS-1985 6

JTS-2260 8

JTS-2285 8

Mat. : Copper Alloy-Nickel plated

Used with general purposematerial.

Hard-wear tip - Type H

REF. d

JTH-1940 6

JTH-1960 6

JTH-1985 6

JTH-2260 8

JTH-2285 8

Mat. : Carbide-based

Glass filled or other abrasivematerials can be handled by thehard wear resistant tip, with itsexceptional combination of hard-ness and thermal conductivity.

Thru-hole tip - Type O

REF. d

JTO-1940 6

JTO-1960 6

JTO-1985 6

JTO-2260 8

JTO-2285 8


For excellent results with plasticsparticularly prone to weld lines,the thru-hole tip is recommended.

No-hole tip - Type B

REF. d

JTB-1940 6

JTB-1960 6

JTB-1985 6

JTB-2260 8

JTB-2285 8


Used to align the flow lines.

d

d

d

d

REF F ø B ø C ø D ø E ø d ø G h k m

GM - 1940 40,3 42,5 48 51,5 36 19 36 46 12 12,8

GM - 1960 59,8 49 54,5 58 36 19 36 46 14 21,3

GM - 1985 85 49 54,5 58 36 19 36 46 14 21,5

GM - 2260 59,8 52 57,5 61 39 22 39 49 14 21,3

GM - 2285 85 52 57,5 61 39 22 39 49 14 21,5

Gating

How to order1. a specific tip : specify the required reference number (REF.)

Tips always to be ordered separately.2. a complete Gate Mate : see page 9.

For Compact, Standard, Jumbo

Type S, H and B Type O

REFType S, H and B Type O

X X

GM - 1940 0,3 0,8GM - 1960 0,3 0,8GM - 1985 0,5 0,8GM - 2260 0,3 0,8GM - 2285 0,5 0,8

H7

R8

ø d

ø

0.2

cyl

90°

X2

30°m

30°

H7

R

ø3.5

0.5

cyl

30°

X

ø

ø d

m

30°

ø Min - 1 mmMax - 3 mm

ø Min - 1 mmMax - 5 mm

(Hot: X ~ 0)

Rev. 05/97

REF.REF. REF. REF.

forSUB-

ASSEMBLYCompact Standard Jumbo


Gate Mates - GM

Bushings for Gate MatesDesigned to facilitate mold construction, this new productoffers the moldmaker a ready-to-use gate insert. Theinsert bushings are available for Gate Mates having an A-dimension of 40 mm, 59,5 mm (=60) or 84.5 mm (=85).All bushings are delivered with a gate opening of 1 mmand are easy to adjust to any larger diameter by themoldmaker. Use only for type S, H and B.

30°

1.5

R5

J

11

4 0+0.

2

21

H

ø G

ø F

ø D

ø E

ø B

ø AH7

+0.2-0

min

H7

±0.5

3 x 45°


Square coilheater

Cast-inheater

GMC-2285GMD-2285

SCH-2285220V/650W

GMC-2260GMD-2260

SCH-1985220V/550W

GMC-1985GMD-1985

SCH-1960240V/450W

GMC-1960GMD-1960

GME-1940GMF-1940

GME-2260GMF-2260

GME-1985GMF-1985

GME-1960GMF-1960

TC-19 GMC-1940GMD-1940

GMC-1960GMD-1960GMC-1985GMD-1985

TC-19

TC-19

GMC-2260GMD-2260GMC-2285GMD-2285

SCH-1940240V/400W

GMC-1940GMD-1940

SCH-2260220V/550W

CIH-1940220V/400W

CIH-1960220V/450W

CIH-1985220V/550W

CIH-2260220V/550W

GME-2285GMF-2285

CIH-2285220V/650W

Thermocoupletype J

Types

J

Ø M

Ø E

Ø A

Ø K

L±0.05

+0.

2-0

REF. Ø A Ø K Ø B J L Ø E Ø M Ø D Ø F Ø G H

BGM-1940 18 39 42 29,5 40,3 55 48 59 48 42,5 26,3

BGM-1960 18 39 42 49 59,8 62 54,5 66 54,5 49 26,3

BGM-1985 18 39 42 74 85 62 54,5 66 54,5 49 26,3

BGM-2260 18 41 44 49 59,8 62 57,5 66 58,5 52 26,3

BGM-2285 18 41 44 74 85 62 57,5 66 58,5 52 26,3

Spare PartsGate Mates

Rev. 05/97

SCHSpare parts


Mini Gate Mates - GMB

Mini Gate MatesThe Mini Gate-Mates are ideal for cast cycling singlecavity molds. The compact design permits shorter overallstack-up of the "A" side mold plates. The Mini GateMates are provided with either a square coil heater or acast-in heater. Thermocouple position provides betterheater control and the overall body design improvesthermal insulation.

How to orderTo order a complete Mini Gate Mate, select the requiredbody and heater type which results in finding the correctreference number.

RemarksTip is made of copper-berylium and is not recommended forabrasive materials. For applications involving highlyabrasive engineering grade resins, contact D-M-E.

Types

Installation instructions

Body Body Heater TC type "J" Tip


REF.Assembly

GMB 0106 ◆ SCH 0004 TCG 0100 GMT 0100GMB 0107 ◆ SCH 0004 TCG 0100 GMT 0100

Body Body Heater Tip


GMB 0101 ◆ CIH 0100 GMT 0100GMB 0102 ◆ CIH 0100 GMT 0100

REF.Assembly

Gating

(*)F = A + AA = A x (11,4 x 10-6) x TT = T max °C - 20 °C

Mini with square coil heater

Mini with cast-in heater

Square Coil heater

REF. Volt Watt For

SCH 0004 230 230GMB 0106GMB 0107

Cast-in heater

REF. Volt Watt For

CIH 0100 230 230GMB 0101GMB 0102

Thermocouple type "J"

REF. For

TCG 0100GMB 0106GMB 0107

Tip

REF. For

GMT 0100GMB 0106/0107GMB 0100/0102

CIH TCG GMT

GMB

SCH

GMB

TCG

GMT

R12,7

Ø 3

8,1Ø 1

5,87

50.8

34.9(A)

CIH

GMB

GMT

Ø 3

8,1

R12,7

50.8

34.9(A)

Ø 1

5,87

±0,

2

H7

±0,

2

H6

±0,

2

Ø 3

5

Ø 3

8,1

Ø 4

1

10.2

(*) F

Ø 1

5,87

30°

Ø 2

8,5

1

7

H6

2

R 3.2

Ø 15,87

30°

30°

10.2

Ø 0,8 min

90°

(**)

0,1

max

cyl

.

R12,7

R12,7

30

Ø 24

7575

30

Ø 27

R0

R0


High Performance Nozzles - CIA

Note: Dim A' refers to extendedsprue gate tip.

* To be ordered separately.

Note: Dim A' refers to extendedsprue gate tip.

* To be ordered separately.

Types

Body Seal ring Cast-in heater Band heater withwith TC type 'J' TC type "J"


REF.Sub-Assembly

To be orderedseparately

CIA 0001 EX ◆ CIH 0081CIA 0002 EX ◆ CIH 0082CIA 0003 EX ◆ CIH 0083CIA 0004 EX ◆ EHR 0154 CIH 0084 BHF 2038CIA 0005 EX ◆ CIH 0085CIA 0006 EX ◆ CIH 0086CIA 0007 EX ◆ CIH 0087

Body Seal ring Cast-in heater Band heater withwith TC type 'J' TC type "J"


REF.Sub-Assembly

To be orderedseparately

CIA 0008 EX ◆ CIH 0088CIA 0009 EX ◆ CIH 0089CIA 0010 EX ◆ CIH 0090CIA 0011 EX ◆

EHR 0155CIH 0091

BHF 2050CIA 0012 EX ◆ CIH 0092CIA 0013 EX ◆ CIH 0093CIA 0014 EX ◆ CIH 0094CIA 0015 EX ◆ CIH 0095

REF. A A'Sub-Assembly

CIA 0001 EX 50,79 69,84

CIA 0002 EX 63,49 82,54

CIA 0003 EX 76,19 95,24

CIA 0004 EX 88,89 107,94

CIA 0005 EX 101,59 120,64

CIA 0006 EX 126,99 146,04

CIA 0007 EX 152,39 171,44

REF. A A'Sub-Assembly

CIA 0008 EX 50,79 69,84

CIA 0009 EX 63,49 82,54

CIA 0010 EX 76,19 95,24

CIA 0011 EX 88,89 107,94

CIA 0012 EX 101,59 120,64

CIA 0013 EX 126,99 146,04

CIA 0014 EX 152,39 171,44

CIA 0015 EX 177,79 196,84

High Performance NozzlesThe CIA High Perfomance Nozzles with cast-in heaters,developed exclusively for D-M-E, can be used for all ap-plications, especially engineering grade resins with ahigh degree of crystallnity. In combination with a bandheater they are also suitable for direct part gating insingle cavity molds. The High Performance Nozzles aredelivered with a seal ring. The radius has to be made bythe customer.

How to orderTo order a complete High performance nozzle for singleuse:1. Select the required series which results in finding the

correct Sub-Assembly REF number.2. Select one of the available tips and state the REF

number.

CIH CIA EHR

Series 250

Series 375EHT CIACIH EHRBHF

Ø 1

7,55

Ø 3

3

Ø 5

0

25.4

A

A'

Ø 9

,52

Ø 2

2

EHRCIH CIAEHT BHF

Ø 3

8

Ø 1

6

Ø 6

,35

A'

A

25.4

Ø 2

7

Ø 1

4,35

3. Select one of the available band heaters and state teREF number.

The 3 REF numbers are required to get the right delivery.

Rev. 05/97

A'

10°

Ø d

Ø T

C

L'

A

Ø d

Ø T

C

L

10°

AL

Ø T

A

L

Ø T

Ø d



TipsSprue gate tip

Used where a sprue on the part or runner is not objectionable. Itsunrestricted channel is recommended for molding filled material, orlarger parts requiring maximum flow.

Extended sprue gate tip

Identical to the Sprue gate tip but provides extra stock on front facefor machining runner profiles and part contours.

REF. d T L' C Series

EHT 0013 EX 2,0 12,5 25,4 28,6EHT 0014 EX 2,0 19,0 25,4 28,6 250EHT 0015 EX 2,0 25,0 21,6 28,6EHT 0019 EX 3,2 12,5 25,4 28,6EHT 0020 EX 3,2 19,0 25,4 28,6 375EHT 0021 EX 3,2 25,0 25,4 28,6

Used where a small circular gate mark is permissible. Nickel platedberyllium copper gate tip controls plastic flow, provides uniform heattransfer and improves gate cosmetics.

REF. d T L Series

EHT 1001 EX 1,5 9,5 4,75EHT 1002 EX 2,0 9,5 4,75EHT 1003 EX 1,5 12,5 4,75

250

EHT 1004 EX 2,0 12,5 4,75EHT 1006 EX 2,0 12,5 5,85EHT 1007 EX 2,5 12,5 5,85EHT 1008 EX 2,0 19,0 5,85EHT 1009 EX 2,5 19,0 5,85

375

EHT 1037 EX 2,0 25,0 5,85EHT 1038 EX 2,5 25,0 5,85

REF. d T L C Series

EHT 0010 EX 2,0 12,5 6,35 9,52EHT 0011 EX 2,0 19,0 6,35 9,52EHT 0012 EX 2,0 25,0 2,54 9,52

250

EHT 0016 EX 3,2 12,5 6,35 9,52EHT 0017 EX 3,2 19,0 6,35 9,52 375EHT 0018 EX 3,2 25,0 6,35 9,52

Point gate tip

Eliminates circular gate marks and provides optimum gate cosmetics.Also features nickel plated beryllium copper gate and carbide tips.

REF. d T L Series

EHT 0005 EX CU - Be 9,5 2,5EHT 0041 EX Carbide 9,5 2,5 250

EHT 0039 EX CU - Be 12,5 2,5EHT 0042 EX Carbide 12,5 2,5

375

Band HeatersBHF

Band heaters with thermocouple type 'J' for nozzlehead (option for series 250 & 375)

REF. H D Watt Series230 V

BHF 2038 20 38 170 250BHF 2050 20 50 190 375

Spare partsCast-in heaters with thermocouple type 'J'

850

47.5

LØ

ID

Ø D

Length of wires 850 mmBlack wire 230 VBlack wire 230 VWhite wire +Red wire - } thermocouple type 'J'

REF. For L ID DWatt

Series230V

CIH 0081 CIA 0001 EX 52,37 275CIH 0082 CIA 0002 EX 65,07 320CIH 0083 CIA 0003 EX 77,77 370CIH 0084 CIA 0004 EX 90,47 15,85 26,97 390 250CIH 0085 CIA 0005 EX 103,17 460CIH 0086 CIA 0006 EX 128,57 460CIH 0087 CIA 0007 EX 153,97 500CIH 0088 CIA 0008 EX 55,42 370CIH 0089 CIA 0009 EX 68,12 415CIH 0090 CIA 0010 EX 80,82 500CIH 0091 CIA 0011 EX 93,52 640CIH 0092 CIA 0012 EX 106,20

22,20 33,32735

375

CIH 0093 CIA 0013 EX 131,62 825CIH 0094 CIA 0014 EX 157,02 920CIH 0095 CIA 0015 EX 182,42 1000

EHT

EHT

EHT

EHT

CIH

HØ D

Ring gate tip

Rev. 05/97

TH6

A +

A

d

~0.

5

4.5

2.5

0,15

R

30°




Sprue, andRing gate nozzle

H7

H6

A +

A

Ø d2

Ø d1

L T

30°

Series A B C D E Fmax

250 45 60 44 38 30 3375 55 75 55 50 40 2

H7

±0,2

20 Ø B

Radius to be made by customer

F

20

45

A

2,5

Ø D

35

H

Ø E

Ø D

Ø C

Installation InstructionsNozzle Head

Series d1 d2 L Expansion

250 30 38 2375 40 50 2 A = A x (11,4 x 10-6) x t

ExtendedSprue Gate nozzle

Point gate nozzle

Series d T R Expansion

250 1,5/3 9,5 3,2375 2,0/4 12,5 4,7 A = A x (11,4 x 10-6) x t

Rev. 05/97

to be ordered separately

(R 15/R 40)18

(R 0)15 20

R15/40

53.5

80

63.5

ø 3

5

ø 3

2

g6


Thermag - HD

Types

Closed chamber

cartridge heaterwith TC

REF. R

HD 80-250-GV/TC/0 0

HD 80-250-GV/TC/15 15

HD 80-250-GV/TC/40 40

Open chamber

cartridge heaterwith TC

REF. R

HD 80-250-OV/TC/0 0

HD 80-250-OV/TC/15 15

HD 80-250-OV/TC/40 40

BenefitsThe Thermag, a full steel single bushing, was primarilydesigned for single cavity molds with direct part gating ofcommodity plastics. Its sharp hardened torpedo tipleaves on the plastic part only a minimal gate vestige,about one-third in height of the gate diameter. Besidethe excellent cosmetic appearance of the gating, theThermag is also very compact with its maximum outsidediameter of 35 mm (band heater excluded).The Thermag uses a probe cartridge heater similar tothat used in the D-M-E Cool-One System. This wellproven concept found its way back to single bushings.Hardened body and torpedo give a long endurance lifealso for abrasive materials.

Special usesParticularly suited for bulk plastics, reinforced or not.The closed chamber option is recommended when awitness ring on the plastic part is acceptable. The openchamber avoids the witness ring and is recommended foroptimum gate cosmetics. Also applicable on ribs, bossesand curved faces.

The Thermag is made of hardened wear resistant steel.Its unique torpedo is specially designed for a smoothmolten plastic flow.Two heating zones:One cartridge heater in torpedo and one heater band forthe distributor cap for perfect heating and control.


● for excellent gate vestige

● for perfect gate cosmetics also on ribs,bosses and curved faces

● for a compact construction

● for direct part gating

● for abrasive materials

● for a smooth molten plastic flow

● for perfect heating and control● for a long endurance life

to be ordered separately

80

ø 1

2

1.5

30

R15/40

(R 0)15

(R 15/R40)18

ø 3

2

ø35

ø 3

0g6 g6


Thermag - HD


REF. Di Da L Volt Watt

HB-15 32 34 16 220 100

Heater band without thermocouple

Gating closed chamber

1 10

45°

Ø 30

Ø 12

H7

H7

Gating

R F

0 80 +0,0515/40 83 +0,03

R F

0 80 +0,0515/40 83 +0,03

F

ø 28

58

ø 71

10

30

ø 90

12 mm width

H7

+0.

05

+0.

05

12 mm width

ø 90

F

30

10

ø 28

ø 71

58

H7

+0.

05

+0.

05

Gating open chamber

R8

Ø 21

Ø 30

10

H7

Ø 1.2

46°

30°

1.2

0.2

Spare Parts

Distributor cap

REF. R

VD- 0 0

VD-15 15VD-40 40

REF. Volt Watt

HD-250- TC 220 250

Cartridge heaterWith thermocouple

Torpedo

REF. R

TP-80 0

1540

Open chamber Closed chamber

REF. REF.

VK-O VK-G

Rev. 05/97

MEO

MEP

MHD

MHD

15

6

2

4

7

4

3

D/3

ECB

WTOECB

TCM

EHR

BHF1

0

L1

Ø 16

Ø 36

Ø 25

C

6

A

B

10

*

6

45

L

51



● to eliminate runners often associatedwith the multiple injection of small parts

● to realize a uniform heat distributionand temperature profile

● to obtain positive results withdifficult applications

● for multiple point injection inone large cavity

● for optimum gate cosmetics● for a perfect balance of the

melt flow

● for a simplified mold design and construction

● for design flexibility

Multiple Gate Nozzle - MGS

BenefitsThe MGS is a multiple gate nozzle most suitable formultiple gating of small parts in single cavity molds.Providing up to 6 points of sprueless injection, located ona small circle, this self-contained round manifold withMicro Hot-One nozzles offers optimum gate cosmetics.

It is possible to select a nozzle with 2, 3, 4 or 6 gates ona pitch circle of 38 or 60 mm diameter, and differentprobe lengths.Each gate is fed through a Micro nozzle with thermo-couple, which results in a perfect thermal regulation ofeach gate. Therefore the system features a uniform heatdistribution and temperature profile throughout.To obtain a better insulation, titanium distance rings areused.

Other benefits are a perfect balancing of the flows,associated with a simplified mold design andconstruction.The various MGS combinations with different nozzlelengths offer full design flexibility.

Special usesAlthough designed for multiple gating of small parts insingle cavity molds, the multiple gate nozzle is alsohighly recommended for multiple point injection in onelarge cavity where balancing of the melt flow is aproblem.Positive results with difficult applications like thin-walled(0.6 mm) glass filled PPS and glass filled PBT parts havebeen obtained.

(*) To be ordered separately

Types

Multiple gate nozzles

REF. A B C D Nozzles (*)MGS 3802 70 38 20 54/3 2 MEP/MEOMGS 3804 70 38 20 54/3 4 MEP/MEOMGS 6003 90 60 40 72/3 3 MEP/MEOMGS 6006 90 60 40 72/3 6 MEP/MEO

* min. 6 mm

Rev. 05/97

8,551

H

L -6

L -1

6

Ø C

min

30

Ø P

20 m

in

50


Multiple Gate Nozzle - MGS

Installation InstructionsProbes

How to orderTo order a complete Multiple gate nozzle :1. Select one of the available Sub-Assembly reference numbers.2. Select the reference numbers of the corresponding Point gate

or Thru hole tip of the Screw head type.3. Both reference numbers as listed under 1. and 2. are required

to get the right delivery.Remarks: For single application, use the insulating ring WTO3000. Radius to be made by customer. For applications under amanifold, use the seal ring EHR 1150.

Spare Parts

REF. Assembly L+0,02 MMEP 0060 MEP 1060 66 59MEP 0070 MEP 1070 76 69MEP 0080 MEP 1080 86 79

REF. Assembly L1+0,02 M1MEO 0060 65 58MEO 0070 75 68MEO 0080 85 78

P C H70 105 L + 4590 125 L + 45

60°

60°90°

Ø 38 Ø 60

4 tips 6 tips

Point gate Thru hole

Gating

Screw head nozzle - point gate typeMEP

MDS MHD DEP

M12

x1

7

6

L

Ø 1

7

M

Ø 1

6

Screw head nozzle - thru hole typeMEO

MDS DEOMHD

L1

M1

6

7

M12

x1

Ø 1

7

Ø 1

6

Description REF. FOR

Seal ring EHR 1150 MGS 38&60

Band heater BHF-3870 MGS 38

BHF 3890 MGF 60

Support blocks (upper) ECB 0500 MGS 38&60

Support blocks (lower) ECB 0501 MGS 38ECB 0502 MGS 60

Insulating ring WTO 3000 MGS 38&60

Thermocouple TCM 0003 MGS 38&60

Cast-in heater MHD 0044 MEP/MEO 60with TC type "J" MHD 0054 MEP/MEO 70

MHD 0064 MEP/MEO 80

2

1

3

4

5

6

7



● for direct part gating of large and/or deepplastic parts.

● for applications in the automotive industry,large household applications, housings andframes, aircraft parts etc...

● for faster start-ups providing positivetemperature control at gate area with "J" typethermocouples and D-M-E temperaturecontrollers.

● for improved part quality.

● for reduced cycle times.

● for easy installation and operation andextremely reliable. The loss of one bandheater does not stop production, in most casesadjustments possible.

● for any "A" length available between 200 mmand 800 mm. Two standard tips, Point gateand Thru hole tip. Tips are in copper basesalloy with Nickel coating.

● for all unfilled plastic materials. Contact D-M-Efor all applications involving highly abrasiveengineering grade resins.

Autonozzles

FlexibilityD-M-E has developed the so-called "Autonozzle" forsingle applications with Hot Sprue Bushings to producevery large parts, especially for the automotive industry.The nozzle consists of a body and standard interchan-geable tips, of which the geometry has been computerdetermined.

The Autonozzle is heated by several band heaters,which can be relocated depending on the length of thenozzle and the plastic material to be used.

Field-tests have proven the implementation of theAutonozzle very successful. The ratio between price andperformance is also favorable.

For applications with abrasive materials, nozzle and tipcan be protected with a special coating.

● for maximum shot capacity up to 10.000 cm3/sec with good flowing materials.

● for a number of temperature control zonesfrom 2 to 4 according to the length and theapplication.

● for power rating from 1,25 Kw to 4,5 Kwfollowing length and application.

● for uniform temperature profile. If needed,adjustments are very simple.

● for easy maintenance.

Rev. 05/97

j6

M36

x 1

.5

45°0'0"

62

Ø 4

0

Ø 1

,3

SW 4647

27,5

Ø 5

0

Ø 1

6

REF.TC 19

REF. WWatt230V

BHF 2550 25 300BHF 5050 50 600


Autonozzle - AMN

Type

REF.A

REF.A

Sub-assembly Sub-assemblyAMN 0250 from 200 to 250 mm AMN 0550 from 500 to 550 mmAMN 0300 from 250 to 300 mm AMN 0600 from 550 to 600 mmAMN 0350 from 300 to 350 mm AMN 0650 from 600 to 650 mmAMN 0400 from 350 to 400 mm AMN 0700 from 650 to 700 mmAMN 0450 from 400 to 450 mm AMN 0750 from 700 to 750 mmAMN 0500 from 450 to 500 mm AMN 0800 from 750 to 800 mm

Body Band heater Thermocouple


AMN 0250 from 200 to 250 mmAMN 0300 from 250 to 300 mmAMN 0350 from 300 to 350 mmAMN 0400 from 350 to 400 mmAMN 0450 from 400 to 450 mm BHF 2550AMN 0500 from 450 to 500 mm BHF 5050

TC 19

AMN 0550 from 500 to 550 mmAMN 0600 from 550 to 600 mmAMN 0650 from 600 to 650 mmAMN 0700 from 650 to 700 mmAMN 0750 from 700 to 750 mmAMN 0800 from 750 to 800 mm

REF.Sub-Assembly

Gate shell insulator

How to order

To order a complete Autonozzle1. Select the required REF. number of the Autonozzle in

relation with the "A" length and give the "A" length atroom temperature.

2. Select the required REF. number of the tip: point gate orthru hole tip.

3. Indicate the type of plastic material to be molded.

Both reference numbers listed under point 1 and 2 and thedetails of the plastic material to be used are required to getthe right delivery.

e.g.: A = 438 mmThru hole tipMat.: Polypropylene no filter - M.F.I. 25

Order: AMN-0450/438ANT 0002Remarks: PP unfilled M.F.I. 25

GSI

REF.GSI 0033

Material: PolyimideMaximum continuous tempera-ture: 288 °CFor easier color changeWear resistant for non-abrasiveplastic

TipsPoint gate tip

REF. RemarksANT 0001 for minimal gate vestige

REF. RemarksANT 0002 for thru flow spotless gating

Spare parts

Band heaters Thermocouple

ANT

Thru hole tipANT

TCBHF

ANT (*)

Ø 1

644A min 200 mm

j6

60

M36

x 1

.5

Ø 4

0Ø

22

Ø 6

Ø 3

,5

45°0'0"

SW 4647

27,5

Ø 5

0

Ø 1

6

W

Ø 5

9

Ø 5

0,8

13 R

ef

Ø 16

Ø 40

AutonozzleAMN


Autonozzles - AMN


Point Gate

GatingThru hole Gate

Gating

▲ A = A x ▲T° x 11,5 x 10-6

A + A

A

H7

12

17

1945°

Ø 100

Ø 82

2

20 x

20 Ø 77

Ø 90

H7

R5

A +

A

A

120°

Ø 4019,5

120°

90°

4

max

0,8

Ø 8 max

Ø 77H719

,5

R5

4A

+ AA

120°

Ø 40

120°

90°

4m

ax 0

,8

Ø 8 max

Ø 77


Osco® Single Valve Gate Nozzle - SCF/SCB


● for today's high technology molding.

● for more flexibility and better results in anymolding application.

● the most trouble free and easy to installsystem.

● shaft-driven 1:1 ratio provides longer compo-nent life and safer operation.

● unique pin guide eliminates gate wear.

● external pin adjustment simplifies machiningand mold assembly requirements.

● simplified design allows for easy installation.

● self energizing pin seal makes the nozzle leakproof and is replaceable.

● unique pin guide maintains concentricity withinthe opening, eliminating gate wear commonlyseen with other systems.

How it worksThe linear actuation of the cylinder is directly transferredto the valve pin thru a drive shaft, which opens andcloses the valve pin as the cylinder is energized in onedirection or the other. The motion of the valve pin isaccomplished without using any kind of lever arm, whichwould greatly multiply the force of the cylinder, causingpremature failure of the components. Since the systemuses a 1 to 1 ratio the force to which the valve pin isactivated is always safe and known.

Adusting the valve pin:The externally mounted cylinder is piloted axially withthe drive shaft, and the mounting hole is slotted allowingthe cylinder to be rotated in either direction. Whilemaintaining the cylinder energized and locked in theclosed position the valve pin can then be easily adjustedby loosening the mounting screw and rotating thecylinder one way or the other. This unique feature totallyeliminates the need for delicate machining andpositioning of the components as required with othersystems. The cylinder is supplied with a dial showing theposition of the valve pin allowing you to see where thevalve pin is and how fast the valve pin is opening andclosing.

Special usesWith its wide range of gate diameters, the Osco® SingleValve Gate Nozzle is suited for medium size to verylarge molded parts, in most plastic materials, unfilled orfilled. The large melt channel allows the use of shear-sensitive resins. The two powerful band heaters providethe possibility of a 2-zone accurate temperature control,necessary for materials with a sharp melting point. Withthe choice of a full body or bodyless tip the heat transferat the gate can be adjusted for both amorphous orcrystalline materials.

Rev. 05/97

FBTNBH

SCF

SCV-MBHT

Ø T

O

Ø C

L

A

88,912

,7

Ø E

R 15,5


Osco® Single Valve Gate Nozzle - SCF/SCB

Types

REF. A C E SeriesSCF 2025 63,5 76 9,5 200SCF 2060* 152,4 76 9,5 200SCF 4040* 101,6 88 13 400SCF 4060* 152,4 88 13 400

T L O19 5,84 Min. 1,5725 9,12 Max. 6,3519 5,84 Min. 3,1725 9,12 Max. 7,90

REF.Sub-

Assembly

(*) length to be specified

REF. A C E SeriesSCB 2025 63,5 76 9,5 200SCB 2060* 152,4 76 9,5 200SCB 4040* 101,6 88 13 400SCB 4060* 152,4 88 13 400

T OMin. 1,57

22Max. 6,35Min. 3,17

25Max. 7,90

Remarks: delivered with O min

Remarks: delivered with O min

SCF 2025 ◆ FBT 2025 EX NBH 1515SCV-

SCV 200-SCF 2060* ◆ FBT 2060 EX NBH 1520

MBHTSCV 200- LR EX SCV 200-

SCF 4040* ◆ FBT 4040 EX NBH 20203025

400 HCA SCV 400- 400 HRSCF 4060* ◆ FBT 4060 EX NBH 2025 LR EX

BLTNBH

SCB

SCV-MBHT

Ø T

O

Ø C

L

A

88,912

,7

Ø E

R 15,5

Full BodySCF

BodylessSCB


Body Full Band Band Hydr. Loca- DriveBody heater heater cylinder ting Shaft(*)Tip + TC "J" + TC "J" ring

SCB 2025 ◆ BLT 2025 EX NBH 1515SCV-

SCV 200-SCB 2060* ◆ BLT 2060 EX NBH 1520

MBHTSCV 200- LR EX SCV 200-

SCB 4040* ◆ BLT 4040 EX NBH 20203025

400 HCA SCV 400 400 HRSCB 4060* ◆ BLT 4060 EX NBH 2025 LR EX

REF.Sub-

Assembly

(*) length to be specified

Body Body- Band Band Hydr. Loca- Driveless heater heater cylinder ting Shaft(*)Tip + TC "J" + TC "J" ring


Rev. 05/97

Ø 100

-0+0,013

-0+ 0,025

±0,

025

H7

4 M8 STC Ø 121

13 o

ffset

20

(Series 200 & 400 )

Ø 140,50

1,75

Ø 1

6

Ø 2

8,65

8

73,1

5

76,2

A

Max

3,2

5

18

Ø B

Ø C44

,45

30°0'0"

Ø TCONTACT AREA LAND

REF.

SCV 200-400 HCA

Nozzle L Contact area land Series C B

5,84 4,75 200 76 649,12 6,35 400 86 76


Osco® Single Valve Gate Nozzle SCF/SCB


Full Body tips

REF. For Series

FBT 2025 EX SCF 2025 200FBT 2060 EX SCF 2060FBT 4040 EX SCF 4040 400FBT 4060 EX SCF 4060

Gating

Spare parts

Bodyless tips

REF. For Series

BLT 2025 EX SCB 2025 200BLT 2060 EX SCB 2060BLT 4040 EX SCB 4040 400BLT 4060 EX SCB 4060

Band heaters withthermocouple type 'J'

REF. Watt 230V For SCF/SCB

NBH 1515 310 2025NBH 1520 440 2060*NBH 2020 580 4040*NBH 2025 600 4060*

Band heaters withthermocouple type 'J'

REF. Watt 230V For SCF/SCB

2025SCV-MBHT 740 2060*

3025 4040*4060*

* 2 heaters per unit

Hydraulic cylinders

Includes:- Viton rod seals- Teflon piston seal (self-energized)- Hardened gear and rack assembly

Locating rings

REF. Series

SCV 200-LR EX 200SCV 400-LR EX 440

Drive shafts

REF.

SCV 200-400 AR

Bodyless type

FBT BLT NBH SCV-MBHT

SCV-LR SCV-ARSCV-HCA

+0,013-0-0

+0,013

60°0'0"

120°0'0"

120°0'0"

Ø 16

T

6,4

2,5

Ø 6,35 Ø 7,92

3,2

7,9

T

Ø 22

120°0'0"

120°0'0"

60°0'0"

M8x1,2512 deep

29,56

19,5

3

79,4

57

57

8

96,5

Ø 2

8,58

12,7

Rev. 05/97

400°

200° C 200° C

400°

200° C

400°

T° T° T°

2 22

l=20 l=20l=7

l=7 l=0,35l=20

Q = 400 w/cm Q = 207 w/cm Q = 22 w/cm

0,3

0,3

0,40,5

T1

T2

1 mm

T1

T2

1 mm1 mm

T2

T1


Micro Single Bushings - MPP/MDO


● to avoid gate freezing

● to permit larger shots and fill faster

● to save on raw materials and waste treatmentcost

● to save on energy

● to solve cooling problems

● to produce top quality moldings in optimalconditions

1) 2) 3)

BenefitsThe Micro Single Bushings are especially designed forextreme conditions. Both bushing and heater are designedfor very limited space. A comprehensive range of differentbushings with point gate tips, respectively thru hole tips, aswell as different steel qualities provide the user a fullspectrum of design capabilities. A new single bushing withsupporting head and exchangeable tip was designed for thedirect part gating in narrow access cavities.

The advantage of this Micro system lies in the application ofthe new D-M-E designed and patented heater elementgeneration. These heating elements have a special multi-layer design which results in 60% less heat losses to themold. This allows for a lesser wall thickness for the sameheat power as e.g. in conventional cast-in heating elements.Due to a superior far more homogenous temperaturecontrol, reacting promptly on temperature deviations in thebushing, this system is also most suitable for use on difficultraw materials.

Special usesThe superiority of this new heating system has been largelydemonstrated and proven to the users by extensivesuccessful applications of engineering materials such as:Delrin, Trogamid, PC, Ryton R4, Desmopan, etc. ....

The termal insulated heaterThe key to succes in heating runnerless systems for extremespecifications.

The cast-in Micro system heater elements are, due to theirmulti-layer construction today's most performant system forheating nozzles on the market.

The figures 1), 2) and 3) explain the differences with conven-tional cast-in heater elements and illustrate typical conductionheat losses between inner (T1) and outer (T2) surface of anheater sheath. These losses influence the cooling require-ments in the mold, and the energy supply, required for aconstant temperature in the melt.

The cast-in heater element 1) against the double layer type 2)shows a double heat loss. Compared to the D-M-E heaterelements of the newest generation, of a multi-layer type, thereis a factor 5 of difference.

The combination with the correct body material 3) ensures thefastest control and lowest overshoots, because the major partof the energy supply will be directed towards the heating ofthe melt.

This means that to maintain a temperature of 250°C atbushing tip, only ca. 270° C are required at the externalsurface of the bushing, compared to 290° C or even 350° Cwhen using conventional heater elements. Due to theconsequently lower energy consumption of the heatingsystem a definitely higher life expectancy of the heatingelements can be expected. This is an advantage that shouldnot be underestimated either.

290°

250°

350°

270°


Micro Single Bushings - MPP/MDO

Type

Ref. Ref. Ref.A Mat.

R = 0 R = 15,5 R = 40MPP 0080 MPP 0081 MPP 0082 45MPP 0090 MPP 0091 MPP 0092 55 StandardMPP 0100 MPP 0101 MPP 0102 65MPP 1080 MPP 1081 MPP 1082 45

WearMPP 1090 MPP 1091 MPP 1092 55

resistantMPP 1100 MPP 1101 MPP 1102 65

Ref. Ref. Ref.A Mat.

R = 0 R = 15,5 R = 40MDO 0080 MDO 0081 MDO 0082 44MDO 0090 MDO 0091 MDO 0092 54 StandardMDO 0100 MDO 0101 MDO 0102 64

Point gate assembly consisting of :

REF.Assembly

Head Head Head Nozzle Flange Band heater TC body Cast-in Insulat. ring Insulat. ring Mat.R = 0 R = 15,5 R = 40 body heater upper lower

Thru hole assembly consisting of :

REF.Assembly

Head Head Head Nozzle Flange Band heater TC body Cast-in Insulat. ring Insulat. ring Mat.R = 0 R = 15,5 R = 40 body heater upper lower

MPP 0080 MEK 0001 DEP 0060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 StandardMPP 0090 DEP 0070 MHD 0054MPP 0100 DEP 0080 MHD 0064MPP 1080 MEK 0001 DEP 1060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 WearMPP 1090 DEP 1070 MHD 0054 resistantMPP 1100 DEP 1080 MHD 0064MPP 0081 MEK 0015 DEP 0060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 StandardMPP 0091 DEP 0070 MHD 0054MPP 0101 DEP 0080 MHD 0064MPP 1081 MEK 0015 DEP 1060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 WearMPP 1091 DEP 1070 MHD 0054 resistantMPP 1101 DEP 1080 MHD 0064MPP 0082 MEK 0040 DEP 0060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 StandardMPP 0092 DEP 0070 MHD 0054MPP 0102 DEP 0080 MHD 0064MPP 1082 MEK 0040 DEP 1060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 WearMPP 1092 DEP 1070 MHD 0054 resistantMPP 1102 DEP 1080 MHD 0064

MDO 0080 MEK 0001 DEO 0060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 StandardMDO 0090 DEO 0070 MHD 0054MDO 0100 DEO 0080 MHD 0064MDO 0081 MEK 0015 DEO 1060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 StandardMDO 0091 DEO 1070 MHD 0054MDO 0101 DEO 1080 MHD 0064MDO 0082 MEK 0040 DEO 0060 MDS 0001 MHD 1000 TCM 0003 MHD 0044 MIS 0002 MIS 0001 StandardMDO 0092 DEO 0070 MHD 0054MDO 0102 DEO 0080 MHD 0064

R15,5

R0

MDS MHD MIS MEKMHD MIS

DEP

TCM

0001 00021000

R40

7

44

42

Ø 4

5

Ø 3

4

Ø 1

7

A

Ø 1

6

R15,5

R0

MDS MHD MIS MEKMHD MIS

TCM

MEO

0001 1000 0002

R40

44

42A

Ø 4

5

7

Ø 3

4

Ø 1

7

Ø 1

6

Point gate typeMPP

Thru hole typeMDO

Rev. 05/97

Point gate type

Ref.

TCM 0003Ref. R

MEK 0001 0

Ref. For

MIS 0001 MPP/MDO

Ref. For Mat.

MDO

DEO 0060 0080/0081/0052DEO 0070 0090/0091/0092 StandardDEO 0080 0100/0101/0102

Ref. For Mat.

MPP

DEP 0060 0080/0081/0052DEP 0070 0090/0091/0092 StandardDEP 0080 0100/0101/0102DEP 1060 1080/1081/1052DEP 1070 1090/1091/1092 wear resistantDEP 1070 1100/1101/1102

Ref. Watt For

230V

MHD 1000 210 MPP/MDORef. For

MDS 0001 MPP/MDO


Micro Single Bushings MPP/MDO


Standard Wear resistant

R = 0 R = 15,5 R = 40 R = 0 R = 15,5 R = 40 A

MPP 0080 MPP 0081 MPP 0082 MPP 1080 MPP 1081 MPP 1082 45MPP 0090 MPP 0091 MPP 0092 MPP 1090 MPP 1091 MPP 1092 55MPP 0100 MPP 0101 MPP 0102 MPP 1100 MPP 1101 MPP 1102 65

Gating


Standard

R = 0 R = 15,5 R = 40 A

MDO 0080 MDO 0081 MDO 0082 44MDO 0090 MDO 0091 MDO 0092 54MDO 0100 MDO 0101 MDO 0102 64

Gating

Spare parts

Flanges Cast-in heaters with thermo-couple type 'J' for nozzles

Band heaters for body

Ref. Watt For For

230V MPP/MDO MPP/MDO

MHD 0044 175 0080-0081-0082 1080-1081-1082MHD 0054 190 0090-0091-0092 1090-1091-1092MHD 0064 200 0100-0101-0102 1100-1101-1102

Body screw head nozzles, pointgate type

Body screw head nozzles, thruhole type

Lower insulating rings

Ref. For

MIS 0002 MPP/MDO

Upper insulating rings Body micro single bushings Thermocouple type 'J' for body

MDS MHD MHD

DEP DEO MIS

MIS MEK TCM

+0.

05

± 0

,05

H7

H7

H7

-0 +0,

1

Ø 17,25

Ø 17

A +

42

A

3

37

Ø 34

Ø 48

10

Ø 0,6 min

6

0,15

34°0'0"

45°0'0"

Ø 17

Ø 17,25Ø

16

Ø 8

Ø 17

R

+0.

05

± 0

,05

H7H7

H7

-0 +0,

1

max Ø 2,0

Ø 17

Ø 17,25

3A

+ 1

37

A +

42

Ø 34

Ø 4845°0'0"

34°0'0"

0,15

10

Ø 3,4

min Ø 0,8

Ø 17,25

Ø 17

30°0'0"6

Thru hole type

Rev. 05/97

LDPE ABS

PC

Ø 4,5Ø 1,5

12 17

5

Ø 6Ø 3

400

60

35

300 200

100

LDPE ABS PC

2

3

5

Ø 1,5

40

100

200

Ø 4,5Ø 3

10

20 LDPE

ABS

15

50

80

25

40

4

1.5

Ø 2.1Ø 1.2 Ø 3

1

5

PC

ABS

LDPE20

10

Ø 1,5 Ø 3 Ø 4,5

35

80

180

3

5

2

LDPE

ABS

PC

2

3

5

Ø 1,5

40

100

200

Ø 4,5Ø 3

10

20

PC

ABS

LDPE20

10

Ø 1,5 Ø 3 Ø 4,5

35

80

180

3

5

2


Process Data Sheet

Flow capacityThese maximum melt discharge flow values apply to the D-M-Ebushings only and were obtained by using mathematical modelsand through experience. Three representative unfilled resins wereconsidered, and it was assumed that the molded part was not alimiting factor by its geometry or e.g. wall thickness. The con-straints limiting the flow through the bushing and the gate were thecommonly accepted peak values for the shear rate and stress, themelt temperature and its increase by friction, and/or the totalpressure drop. The actual results obtainable with the D-M-E HotSprue bushings depend on a large variety of factors on whichD-M-E has no control like type of plastic materials, fillers, molddesign, injection machine, molding parameters etc...Therefore, D-M-E is giving this information only as generalguidelines and no warranties are expressed or implied. In case ofdoubt, D-M-E will be pleased to give any advice and assistance.

GM

GMB

HD

All Straight Shots

Gate Mate Jumbo (ø 22)

Mini Gate Mate

Thermag

High performance NozzleCIA

Series 250 High performance NozzleCIA

Series 375

me

lt flo

w c

m3/s

ec

gate

me

lt flo

w c

m3/s

ec

gate

me

lt flo

w c

m3/s

ec

gate

me

lt flo

w c

m3/s

ec

gate

me

lt flo

w c

m3/s

ec

gate

me

lt flo

w c

m3/s

ec

gate

SSBU

LDPE ABS PC

2

5

3

180

80

35

Ø 4,5Ø 3Ø 1,5

10

20

GMGate Mate Compact & Standard (ø 19)

me

lt flo

w c

m3/s

ec

gate

Rev. 05/97

LDPE

ABS

PC

0,8

Ø 1,5

8

40

2

Ø 2,0Ø 1,0Ø 0,8

0,4

18

Ø 6Ø 3

80

Ø 5Ø 2

120

170

50

Ø 4

600

350

2000 1000

LDPE ABS

PC

1000 2000 3000

350

600

Ø 5 Ø 8

50

170

120

Ø 3,5 Ø 6

80

Ø 4 Ø 7

PC

ABSLDPE

LDPE

ABS

PC

0,8

Ø 1,5

8

40

2

Ø 2,0Ø 1,0Ø 0,8

0,4

18

PC

ABS

LDPE

20

0,4

Ø 0,8 Ø 1,0 Ø 2,0

2

50

10

Ø 1,5

1

Osco® Single Valve Gate NozzleSCF/SCB

Series 4040-4060


Process Data SheetMGS MGS

SCF/SCBSeries 2025-2060

Multiple Gate Nozzle / Point gate tips Multiple Gate Nozzle / Thru hole tips

Osco® Single Valve Gate Nozzle

Micro Single Bushing / Thru hole tipsMDO

Micro Single Bushing / Point gate tipsMPP

me

lt flo

w c

m3/s

ec

gate

me

lt flo

w c

m3/s

ec

me

lt flo

w c

m3/s

ec

gate

me

lt flo

w c

m3/s

ec

me

lt flo

w c

m3/s

ec

me

lt flo

w c

m3/s

ec

me

lt flo

w c

m3/s

ec

gate

me

lt flo

w c

m3/s

ec

gate

PC

ABS

LDPE

20

0,4

Ø 0,8 Ø 1,0 Ø 2,0

2

50

10

Ø 1,5

1

500

Ø 4

100

Ø 2 Ø 5Ø 3 Ø 6

1000

400

800

PC

ABS

LDPE

AMN AMNAutonozzle / Point gate type Autonozzle / Thru hole type

gateØ 7Ø 6Ø 4

400

Ø 8Ø 5

1600

500

10000

1000

100

50

4000

LDPE

ABS

PC

gate

gategate


Process Data Sheet

Selecting the right Hot Sprue BushingRegarding the plastic material

The actual results obtainable with the D-M-Erunnerless systems depend on a large variety offactors on which D-M-E has no control, like type ofplastic materials, fillers, mold design, injectionmachine, molding parameters etc ...

Therefore, D-M-E is giving this information only asgeneral guidelines and no warranties are expressedor implied. In case of doubt, D-M-E will be pleased togive any advice and assistance.

Plastic Material PE PP PS SB PA PMMA ABS POM PETP PPS SAN PC PBT PSU PEEK PEI Gate Vestige

Excellent Good On condition Not recommended

SSBUStraight Shot Standard

SSBUStraight Shot Mini

SSBUStraight Shot Pico

SSBUStraight Shot Ext. Pico

GM Gate Mate Tip S

GM Gate Mate Tip H

GM Gate Mate Tip O

GMB Mini Gate Matewith Sq Coil heater

GMB Mini Gate Matewith cast-in heater

CIA High performance nozzlewith Sprue gate tip

CIA High performance nozzlewith ring gate tip

CIA High performance nozzlewith Ext. Sprue gate tip

CIA High performance nozzlewith Point gate tip

HD Thermag

MGS Multiple Gate nozzlePoint gate typ

MGS Multiple Gate nozzleThru hole typ

AMN AutonozzlePoint gate type

AMN AutonozzleOpen type

SCF Osco® Single Valvegate - Full Body

SCB Osco® Single Valvegate - Bodyless

MPP Micro Single BushingPoint gate type

MDO Micro Single BushingThru hole type

Rev. 05/97

Maximum shot weight in grams with a maximum orifice diameterViscosity

High Medium Low


Process Data Sheet

Selecting the right Hot Sprue BushingRegarding the shot weight

These maximum shot weights per probe or nozzle aregiven as an indication only, assuming normal injectiontimes, favorable molding shapes and wall thicknesses.

These maxima may be lower for instance in case offast cycling molds, for thin walled products, or evenhigher in cases where long fill times are admissible.

SSBUStraight Shot 110 400 1200

GMGate Mate ø19 90 250 800

GMGate Mate ø22 180 500 1500

GMBMini Gate Mate 40 180 400

CIA - High performance nozzlesSeries 250 120 400 1200

CIA - High performance nozzlesSeries 375 150 600 1500

HDThermag 10 60 160

MGSThru hole tips 20 50 130

MGSPoint gate tips 15 40 120

AMNAutonozzle point gate tips 6000 12000 30000

AMNAutonozzle Thru hole tips 2000 3000 5000

SCF/SCB - Osco® Single ValveGate - Series 2025-2060 750 1800 4500

SCF/SCB - Osco® Single ValveGate - Series 4040-4060 900 2200 6000

MPP - Micro Single BushingPoint gate tips 15 40 120

MDO - Micro Single BushingThru hole tips 20 50 130

Plastic modality table(Unfilled resins)

PE

PP

PS

SB

PA

PMMA

ABS

POM

PETP

PPS

SAN

PC

PBT

PSU

PEEK

PEI

Low viscosity (easy flow)

Medium viscosity

High viscosity (stiff flow)

Remark: Addition offillers e.g. glassfibres may changethe viscosity con-siderably.

Engineering plastics viscosity

Engineering plastics:Average process temperature and melt viscosity at 1000 sec-1 shear rate

Viscosity µ (NSM-2 at 1000 sec.-1)

PEI

PEEK PSU

PCPPS

PPO

PA66PA6

ABSPOM

PET

PBT


Case studies

Systems used Applications

Product : Housing forgrinding wheel

Number of cavities : 1Material : PA 6/6 30 GFPart weight : 120 grRemarks: insert molding

Product : Beaker

Number of cavities : 1Material : PCPart weight : 60 grRemarks: Tip S

Product : Cup

Number of cavities : 1Material : SANPart weight : 33 gr

Product : Toolbox

Number of cavities : 1Material : ABSPart weight : 850 gr

D-M-E EUROPE • Industriepark Noord I • B-2800 Mechelen • Tel. +int. 32.15 / 21 50 11 • Fax +int. 32.15 / 21 82 35

8 / 8024038 - 0697 - E Printed in Belgium - MD75485

Molding Systems

Hot Sprue Bushings• Straight Shot• Gate Mate• High Performance nozzle• Thermag• Multiple Gate Nozzle• Autonozzle• Osco® Single Valve Gate nozzle• Micro Single Bushing• Process Data Sheets

Runnerless Molding Systems• Separate leaflet

Temperature Controllers• Separate leaflet

MOLDING SYSTEMS

TemperatureControllers

Hot SprueBushings

RunnerlessMoldingSystems

We Build Productivity

hot sprue bushings · pdf file2 rev. 05/97 hot sprue bushings d-m-e hot sprue bushings...

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