Hot Runner Cleaning Agent Composition for Efficient Material Substitution
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Solution Overview
Problem
In hot runner molding, efficiently substituting molding raw materials in the flow channel without the need for multiple purge agent steps is challenging due to the absence of a screw, requiring innovative cleaning agents that can effectively discharge and replace residual materials.
Innovation Solution
A cleaning agent composition comprising 100 parts by weight of thermoplastic resin, 1 to 20 parts by weight of fatty acid esters (glycerin, polyglycerin, or sorbitan fatty acid esters), and 1 to 15 parts by weight of metal salts, which can be added as a master batch to the molding raw material for efficient substitution without separate purge agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a purge agent is used to discharge molding raw material from the hot runner flow channel, then the flow channel can be cleaned, but multiple substitution operations are required and the process becomes complex
Solution Approach 1:
The patent combines the cleaning function and the next material's molding function into a single composition. The cleaning agent contains both cleaning components (purge agents, lubricants) and the next material to be molded, eliminating the need for separate purge and material loading steps. This merging reduces process complexity while maintaining effective cleaning.
Solution Approach 2:
The cleaning agent composition serves multiple functions simultaneously: it cleans the flow channel by discharging residual material, lubricates the flow channel to facilitate smooth flow, and acts as the next material to be molded. This multi-functionality eliminates the need for separate operations and reduces the number of substitution steps required.
2Reliability
If a purge agent is used to discharge molding raw material, then the flow channel is cleaned, but at least two substitution operations are required
Solution Approach 1:
The patent merges the purge agent function and the next material function into a single composition that is injected in one operation. This eliminates the time required for separate purge and material loading operations, reducing total substitution time while ensuring effective cleaning through the combined cleaning components.
Solution Approach 2:
The cleaning agent is designed to perform cleaning action before the next material is molded, with cleaning components that actively discharge residual material. This preliminary cleaning action is integrated into the material injection process itself, eliminating separate time-consuming purge operations.
3Force
If a screw is provided to generate high shear force for discharging material, then material discharge is effective, but the hot runner flow channel cannot accommodate a screw
Solution Approach 1:
The patent replaces the mechanical screw system with chemical and rheological mechanisms. The cleaning agent contains lubricants that reduce friction and viscosity modifiers that change the flow characteristics of the material, enabling effective material discharge through flow dynamics rather than mechanical shear force from a screw.
Solution Approach 2:
The cleaning agent modifies the physical parameters of the material flow by incorporating viscosity reducers and lubricants. These parameter changes enable the material to flow more easily and be discharged effectively from the hot runner flow channel without requiring the high shear force that would necessitate a screw mechanism.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This composition allows for efficient substitution of molding raw materials in hot runner type molds, reducing the number of steps required and enabling quick changes based on material type, with excellent compatibility and lubricating properties, facilitating seamless material exchange.
Implementation Method 1
1 part by weight to 20 parts by weight of at least one type of fatty acid ester that is selected from glycerin fatty acid ester, polyglycerin fatty acid ester, or sorbitan fatty acid ester; and 1 part by weight to 15 parts by weight of a metal salt of a fatty acid and/or a hydroxyfatty acid
Data Source
AI summary
Provided is a cleaning agent composition that is capable of efficiently performing the substitution of a molding raw material in a hot runner type mold. The cleaning agent composition contains 100 parts by weight of a thermoplastic resin; 1 part by weight to 20 parts by weight of at least one type of fatty acid ester that is selected from glycerin fatty acid ester, polyglycerin fatty acid ester, or sorbitan fatty acid ester; and 1 part by weight to 15 parts by weight of a metal salt of a fatty acid and/or a hydroxyfatty acid. The cleaning agent composition is used for cleaning a flow channel for resin in a hot runner type mold.