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In this section, you can access to the latest technical information related to the PISA project topic.

Hot runner system from HRSflow - Class A vehicle windows made of polycarbonate

For thetwo-component injection molding of the rear-quarter windows of polycarbonate forthe Buick GL8 and GL8 Avenir MPVs (multi-purpose vehicles), Chinese Tier 1supplier Shentong uses two hot runner systems from HRSflow. One is forproducing the transparent first component and the other for the partial,seamless overmolding with a dark-colored PC around the edges. Both systemsintegrate the programmable FLEXflow valve gate technology, which enables themanufacturer to achieve the outstanding surface quality specified by the OEMfor these parts. With dimensions of 1,200 x 460 mm, it is currently the world'slargest moulding of its kind. Furthermore, FLEXflow helps to ensure that thewindows - which are around 40 % (3 kg) lighter than comparable parts made ofglass - have very high fitting precision for unproblematical assembly withminimum warpage and very tight tolerances. During the course of the projectdevelopment, HRSflow supported the converter with extensive Moldflowsimulations during optimization of the production parameters for these large,asymmetrical parts.

The two hotrunner systems developed by HRSflow each have a hot runner manifold with tenservo-electrical drives for the nozzles with conical valve gate, integratedinto the clamp platen. The FLEXflow technology from HRSflow used to control thesequential injection process makes it possible to coordinate every singleindividually driven needle precisely to the process and to open and close itwith selectable speeds. This allows absolute precision control both of the meltflow in the individual hot runner nozzles and of the volume flow in the overallcavity so that it is filled evenly and homogeneously. Thanks to the gentleopening and closing of the needles, there is none of that undesired pressuredrop or changes in temperature and flow velocity as can occur with conventionalcascade injection moulding during the sequentially abrupt switching on of thehot runner nozzles. This thus also eliminates unsightly flowmarks on the mouldedpart. The overall result is Class A moulding surface with no optically relevantdefects. The main applications of the FLEXflow technology are the injection mouldingof high-quality complex automotive parts including large-area exterior andinterior components such as spoilers, front ends, instrument panel supports,door trim and headlights as well as wide trunk taillights, plus therear-quarter windows described here made of transparent polycarbonate.

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