Orlando, Fla. — While Incoe Corp. couldn't replicate its most exciting news at its booth in Orlando for NPE2018 --- it's impossible to display your new global headquarters when it is in the process of being constructed --- the hot runner system manufacturer did show off several new hot runner solutions.
Prime among them was the extension of its simplified MultiPower heater to the next generation of nozzles, the DF 8. The concept, introduced a year ago for the nozzles of the DF 12 series, now extends to the DF 8, which has a maximum possible shot weight of between 30-500 grams, depending on the melt viscosity and geometry of the nozzle tip.
The DF 8 covers the small to medium application range, perfect for confined spaces, Incoe said, where there are points deep in the mold that need to be injected with plastic. Applications include speaker grilles for the automotive industry, which are gated through several nozzles.
The MultiPower heaters replace the BH and MH heater combination, which previously formed the basic elements of Incoe's modular heating solution.
According to Jim Bott, Incoe business development manager, the modular heating concept for the Incoe nozzles is to achieve a power-differentiated supply of heat over all available lengths through the appropriate combination of standard heaters in a user-friendly manner.
"That way, you only heat what is necessary to keep the melt in the flow channel at an optimum temperature level," Bott said.
The MultiPower heaters are the perfect solution, the company said, as the heater and associated thermocouple can be changed easily. The additional groove per heating zone is available for a replacement thermocouple (twin thermocouple concept), and all heating wires are positioned under the heater case and are protected.
With a single-assembled design, the MultiPower heaters display stable temperature profile along the flow path, which gives the injection molder optimum processing conditions. This homogeneous temperature profile allows the number of heating zones to be reduced from three to two, not only saving control zones, but also costs, the company said, that can arise due to inadequate temperature control during operation.
Incoe also displayed its slim DF 5 nozzle with a slim base heater. The diameter of the nozzle is almost 25 percent smaller, the company said, therefore allowing the large 5-millimeter-flow-diameter nozzles to be supplied as close as 18 mm apart — or even closer at 16 mm apart with modification to the nozzle shank.
This allows for a tighter pitch spacing, closer proximity of water cooling circuits, reduced radiant heat to the mold, which means reduced cycle times and enhanced mold support.
Incoe has upgraded its GSCmini, a lightweight, timer-based, pneumatically valve gate actuated sequencing controller. Incoe said the GSC2mini can provide valve gate actuation for either pneumatic or hydraulic cylinders.
According to the company, the gate sequence controller is ideal for valve-gated applications that do not require sensors or linear transducer control as well as a low-cost VG actuator within a mold tool room.
The I-Series Pro, with technology based from the I-Series Controller, is new to the temperature controller line. The integrated microprocessor-based temperature controller covers 12 to 96 zones — two zones per card — resulting in a compact footprint.
Incoe said its SoftGate valve pin speed control is an important core product for process optimization through hot runner technology. The flow cross-section is continually opened and released through SoftGate instead of an abrupt opening of the valve gate nozzle. In addition, the nozzle opening time required for optimum quality can be set and reproducibly ensured.
In addition, the control of melt flow during cascade injection molding allows for more coordinated changes in pressure and speed of the melt during the process, resulting in a continuous melt stream.
SoftGate is operated without additional control technology and is easy to implement, the company said. It is available as version 3.2. Incoe said SoftGate achieves the highest surface quality as a result of optimized melt flow, widening the process window.
Incoe, which last month opened a technical service and spare parts center in Querétaro, Mexico, is preparing to move into its new global headquarters in Auburn Hills, Mich., later this summer. The $20 million state-of-the-art project is expected to span 138,000 square feet. The current headquarters is in Troy, Mich.