Introdução ao projeto de ferramentas Prof.

Eduardo Thomazi

Chapter 7 – Injection Systems

The injection system of a mold has the main function of guiding the material
melted to the cavities. Figure 7.1 shows an example of a mold with
four cavities, with the injection channel, the primary distribution channels and
secondary, the channel retention and the injection entries.
Success in the thermoplastic injection process is directly related to
knowledge of the flow of molten material in the distribution channels of the mold. The
concepts mentioned here, as well as to deepen the related topics must be
taken into account for an adequate project to be conceived.

Fig.7.1 - Elements of an injection system

Injection flow
The injection points should be located in order to provide the best
flow conditions and parts in which the mark left by them does not affect efficiency and the
aesthetics of the product or that can be easily removed with subsequent operation.
During the flow, the molten plastic material comes into contact with the wall.
cooled from the mold creating a frozen layer. Where ahead of
flow (Flow Front) passes, it generates this frozen layer, which increases in
thickness increases as the injection time increases. Figure 7.2 presents an illustration
from the flow front generating a frozen layer inside the mold walls.

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Figure 7.2 - Flow front and frozen layer

Figure 7.3 shows an acceleration in the generation of the frozen layer when the
the filling speed is lower. It is concluded that the filling should be
be as quick as possible to avoid injection failures, excess pressure of
excessive injection and recirculation.

Figure 7.3 - Differences between fast and slow filling regarding the formation of the front
flow and the frozen layer
Another interesting situation when analyzing the flow of material is that due to the
Frozen layer injection entry points must be located on the walls.
thicker of the product, as shown in figure 7.4.

Figure 7.4 - Best location of the injection point in relation to the thickness differences of
product

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Figure 7.5 shows several examples of parts with different points of

injection and the flow lines of each one.

Fig. 7.5 – Injection flow in parts with different injection points

The geometric center or center of gravity is the indicated place to locate.
the injection channel. But due to the productivity of the mold, this is not always possible, and
In these cases, the rule is to keep the paths traveled by the molten material as short as possible.

possible.
The last meeting point of the molten material is called the weld line or
cold joint, due to being the coldest and most stressed point of the part, so the more
the smaller the distance between the weld lines, the better stability the piece will have.

Injection Bushings
It is the first area where the molten mass of the polymer is forced to pass through.
after leaving the injector cylinder. The shape and dimensions of the bushing must be such that they do not

causing no damage to the molten material, since it passes through this region with great
pressure and speed.
One of the main problems that a poorly sized bushing can cause to
polymer, it is degradation by shearing.
The shear degradation of the polymer is the loss of its properties.
(mechanical, thermal, etc.) caused by the breaking (shearing) of molecular chains.

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The bushing must follow a conical shape with conicity varying from 2 to 6 degrees.
The conduit must be well polished and as short as possible. At the end of the bushing there should be

a cold well with diameter and depth equal to the largest diameter of the conduit.
Figure 7.3 shows three types of coupling of the injection bushing with the barrel
From the injection machine and in figure 7.4 an example of an injection bushing is presented
pattern removed from the DME company's catalog.

Fig. 7.3 – coupling of an injection bushing.

Fig. 7.4 - Example of an injection bushing.

Distribution channels
The distribution channels transfer the molten material from the nozzle to the inlets.
the cavities. These must be designed to distribute simultaneously to all the
cavities to prevent the poor filling of some cavities. Note in the figure
7.5 some examples of geometrically balanced cavity distribution and
geometrically unbalanced and in figure 7.6 some examples of distribution
leaving an area for storing cold material (cold well).

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UNBALANCED

UNBALANCED

Fig 7.5 – Distribution of geometrically balanced and unbalanced cavities

Fig. 7.6 – Distribution of cavities leaving 'cold well'

Whenever there is a break in the distribution channel, there must be a
area to retain the coldest material, which is called the cold well and serves to absorb the
cooler flow front of the material. In figure 7.7, an example of a distribution
with a cold well

Fig. 7.7 - Distribution channel with cold well

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Types of channels
For a good flow of the material, the choice of the type of channel section is very important.

Importantly. In general, circular channels are more recommended, as

they present a minimal contact surface between the plastic and the mold. In figure 7.8
some types of recommended and not recommended channels are shown.

AWFUL AWFUL REGULAR

CORRECT CORRECT CORRECT

Fig. 7.8 - Types of distribution channels

Figure 7.9 presents an example of sizing for the types of channels.
most commonly used, that is, round, trapezoidal or rounded trapezoidal.

Fig. 7.9 - Sizing of injection channels

Injection Entry Points

The injection entry is an item that deserves extensive discussion in its definition.
injection entry controls the speed at which the molten material enters the cavity

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and also, its packaging. These two characteristics will influence

performance and appearance of the injected part.

Problems arising from the points mentioned above can be eliminated if the
type of entry point (or points) and their location are well defined. This,
basically, it will depend on the design of the part, the flow of the molten material and

requirements for the use of the molded piece.

Some other considerations such as the nature of the polymer (whether crystalline or
amorphous) and whether they are charged or not, should also be taken into account. In the polymers

loaded with fiberglass, due to its anisotropic characteristic, the location of

the entry point must be studied before starting the cutting of the mold in order to
take into account the correct value of the material contraction. Generally speaking, the
the following considerations must be taken into account regarding the entry point of
injection
• Large parts that require multiple entry points, these must be
close enough to avoid pressure loss;
• To avoid gas entrapment, the flow of material from the point of
inlet must be directed to the gas outlets;
• The entry points should preferably be located from
thick walls to thin;
• The entry points must be located in low demand areas.
mechanics of the part;

• The entry points should be located in such a way as to minimize

splice lines and any type of mark;
• To minimize jetting, spraying, and fogging, the input must be
must be at a right angle to the channel and there must necessarily be a well
cold by the canal.
The following are the various types of injection entry points.
used:
a) Direct entry
b) Side entrance
c) Wedge-shaped hammer entry
d) Diaphragm type input
e) Entrance to tunnel or submarine

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f) Submerged or underwater entry

g) Capillary entrance

Direct input
It is widely used for large parts, deep extraction, or walls.
thick areas where the maximum injection pressure is required. One must be careful with
this type of entry point in pieces with rectangular shapes when the material is
Reinforced with fiberglass, distortions may occur due to fiber orientation.
Note in figure 7.10 that there is no distribution channel and that the feeding channel
gets stuck in the part requiring rework.

Fig. 7.10 - Direct input.

Side entrance
It is the most commonly used type in injection molding. The thickness of this
the entry type must be 50% of the wall thickness of the part for non-materials
reinforced, and 70% for reinforced materials. The width of the entry point should be
specific for each material. The entry point length should be shorter or
equal to 1 mm.

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Fig. 7.11 - Side entrance.

Fan entrance
The fan entry is a special type of side entry used for parts.
flattened and thin. The fan extends the flow of the material through the cavity,
standardizing its filling. To achieve better results, the area of the point
The inflow should never exceed the cross-sectional area of the channel.
As a main disadvantage, this type of input generates rework and according to
with the opening of the fan makes it very difficult to separate the product.

Fig. 7.12 - Fan entrance

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Diaphragm type input

There is, furthermore, another type derived from the fan entry, which is the diaphragm entry.

which should be used to minimize warping in large, flat parts. This

the type of input causes significant rework, as it is necessary to have a device to separate the
product channel.

Fig. 7.13 - Diaphragm type inlet.

Tunnel entrance or 'cat's claw'
This type of entry allows for the separation of the channel and the product (deglitching)

automatically during the molding process. In this type of input the pin
The channel extractor should be positioned 5 to 10 mm from the part in order to facilitate the
separation. This type of entry is not used for rigid and reinforced materials (with
load).

Fig. 7.14a - Entrance to tunnel or ‘cat's claw’ - View of the prosthetics

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Fig. 7.14b - Tunnel entrance or 'cat's claw' - Cross-section view

Submerged or submarine entrance

This type of input is widely used because it allows the separation of the channel and the

product (de-shedding) automatically during the molding process.

Fig. 7.15a - Submerged or underwater entrance.

Fig. 7.15b - Submerged or underwater entrance.

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The derivative of this type of entry exists as tunnel entry in the extractor pin when
it could not be located near the part. After injection, the appendix can be
separated from the product manually or by mechanical device.

Fig. 7.16a - Submerged inlet in the extractor.

Fig. 7.16b - Submerged entry in the extractor.

Capillary entry
It is a type of insert used in a three-plate mold. It allows for separation.
automatic of the channels and leaves a finish in the area of the entry point of the piece
very good.

Fig. 7.17 - Capillary entrance.

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In addition to these types of injection already discussed, there are also injection systems with

hot channels, where there is no injection channel production and in most cases the
injection is about the part and the injection mark resembles the type of capillary entrance. This
The system is divided into injection with hot nozzle and with hot chamber.

Hot-bite:
The injection occurs directly onto the part. This system contains a single nozzle.
of injection that is heated by resistances. Note in figures 7.18 and 7.19:

Fig. 7.18 – Hot Bico

Fig. 7.19 – Assembly diagram of a system with a hot nozzle

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Figure 7.19 shows the assembly diagram of a system with a nozzle.

hot.
The injection with hot nozzle has the following main characteristics:
• Remove the injection channels;
• Eliminate the deburring work of the injected parts;
• Increase productivity;
• High cost of the system;

Hot chamber system

The use of hot chamber systems can offer several advantages if
compared to conventional cold channel systems, such as:
COST REDUCTION:
• Economy in the use of raw materials
• Low energy consumption
• Reduced operational cost
• Smaller injection cycle
• Better utilization of the equipment
FLEXIBILITY IN THE PROJECT
• Ease in defining feeding points
• Elimination of the need for channel balancing
• Diversification of material input types
• Development of compact projects
• Greater number and possibilities of injection points
• Wide variety of injection bushings and tips
• Easy to obtain layouts with balanced flow
REDUCTION OF CYCLE TIME
• Reduction of cooling time
• There is no need for branch solidification
• Reduced opening courses
• Reduced injection time
IMPROVEMENT IN THE QUALITY OF MOLDED PARTS
• Exemption from Contamination
• Greater dimensional uniformity in the finished product

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• Injection traces can be controlled and in some cases become

practically imperceptible
• Reduction of injection pressure
• Lower residual stress in molded components
• Elimination of secondary operations
GREATER EFFICIENCY OF THE EQUIPMENT
• Use of machines with lower clamping force capacity and
plasticizing capacity
• Reduction in the number of granulating mills for grinding channels
• Easy change of material and color
• Lower injection pressure
• Lower pressure in the mold
The disadvantage of this system lies in the very high cost of its components.
heating. For implementation, it is necessary to analyze whether the positive factors mentioned above
do they return the investment or not.

Fig. 7.20 - Hot chamber injection system

In figure 7.20, it can be seen that it is possible to inject a piece with various points.

of injection or several parts with one or more points each part.

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Pode-se afirmar que o sistema com câmara-quente nada mais é que um sistema
with various hot tips fed by a plate (usually called
manifold).
Manifolds:
Steel distributor block, with assured quality for your use, with
stable and balanced flows. The manifolds are usually compact and use
flexible tubular resistances presenting a uniform temperature profile to
along its entire length, the internal channels are completely polished and
mounted with threaded plugs. Each manifold is designed following the requirements
specific inner diameter, based on the injection size, type of resin and
flow orientation. This way, the manifold can operate with greater precision, and the
maximum productivity.
There are several configurations of manifolds as can be seen in figure 7.21,
besides those available in manufacturers' catalogs, there is still the possibility of being
custom-made a manifold.

Fig. 7.21 – Example of manifold available in catalogs

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Fig. 7.22 – Assembly of a system with hot chamber

Gas Emission
When a plastic material is molded, it is very important that in the cavity of
molds have efficient gas outlets so that the air can exit when the
molten mass entering the cavity. The gas outlets should be located in the
material flow directions.
Inefficient or poorly located exits may result in poor filling.
from the piece, weak seam lines and irregular contraction of the molding. These problems
they become more critical in thin wall pieces when high speed is used
injection. In some types of molds, gases can get trapped in areas where an outlet
it cannot be built. In these cases, the gas outlet may be made on the extractor pin.
Also, to facilitate the flow of molten material through the distribution channels,
gas outlets may be built in the cold wells.
Figures 7.23 and 7.24 present gas outlet schemes in the line of
mold partition. In the case of flame-retardant materials, it is recommended to construct
continuous gas emissions, more efficient than conventional ones.

Fig. 7.23 – Point gas outlet

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Fig. 7.24 – Cavity with gas outlets

Exercises:
1 – Desenhar um exemplo de cada tipo de entrada de injeção e citar três
characteristics of each one.
2 - Demonstrate two distributions for a mold with 32 cavities.

Bibliography
PROVENZA, Francesco. Plastic Molds. 1a. Ed., São Paulo: Editora F.
Provence, 1976. 210 p.
CRUZ, Sérgio da. Injection molds. 2a. Ed., Curitiba: Hemus Publishing, 2002.
242 p.
HARADA, Júlio. Molds for injection of thermoplastics - projects and
basic principles.1a. Ed., São Paulo: Artliber Publisher, 2004. 308 p.
GLANVILL, A. B., DENTON, E. N.. Injection Molds - Basic Principles and
projects.2a. Ed., São Paulo: Editora Edgar Blücher Ltda., 1989. 308 p.
MICHAELI, Walter,GREIF, Helmut, KAUFMANN, Hans, VOSSEBÜRGER,
Franz-Josef. Plastic Technology. 1a. Ed., São Paulo: Edgar Blücher Publishing Ltd.
2000. 205 p.
MANRICH, Silvio. Processing of thermoplastics. 1a. Ed., São Paulo:
Artliber Publishing, 2005. 431 p.

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