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News

Husky provides hot runner solution for difficult-to-mold medical application

Husky Injection Molding Systems : 02 November, 2006  (Company News)
When Ypsomed AG, a leading medical technology company, needed superior production quality for its pharmaceutical self-injection applications, it turned to Husky Injection Molding Systems. With more than 25 years experience in hot runner systems, Husky was able to provide the company with the technology and expertise needed to process FDA-approved medical resins.
Ypsomed, based in Burgdorf, Switzerland, develops and markets products that allow patients to administer their own medication in a safe and simple way. Its product range spans a wide spectrum, from simple disposable pens to pens with variable dosing and electronic display, to highly complex injectors with multi-functional electronics.

Because they are self-administered, these pens must be robust. Aesthetics are important as well, since they must convey purity and cleanliness, while precision production must be maintained to help ensure that the product consistently injects the exact dosage of medication required. With these requirements in mind, the pen components are made with a resin that offers excellent impact strength, dimensional stability, colorability and clarity.

To process this resin, and to achieve the highest possible production quality and consistency with its existing equipment, Husky engineered and configured a 4-drop hot runner system with Ultra 750 valve-gate nozzles specifically for Ypsomed's processing equipment and production parameters. Husky also optimized the channel layouts and nozzle design for the company's molds. This resulted in faster injection rates and better part quality, with cycle time reductions of up to 20%.

Husky hot runners and nozzle technology provide close control of shear-induced heat, residence time of the resin in system, system pressure and gating. And the thermal design of Ultra nozzles provides a wide operating window, allowing the resin to be processed at lower temperatures compared to alternative technologies.

Together with Husky's optimized hot runner channel layout, the Ultra nozzles significantly reduced scrap related to burn marks. A further engineering advantage of Husky Ultra technology is its positive seal-off, important because the resin used can require injection pressures of 2,000 bar or higher. The patented UltraSeal spring in Husky nozzles preloads the nozzles to ensure seal-off, preventing leakage during start-up, operation and mold or color changes. In addition, the UltraSealspring seal-off minimizes heat transfer from the nozzle stack and hot runner manifold plate to the cavity plate, so that the cavity plate temperatures remain consistent.

In other, less thermally-demanding injection molding processes, UltraSeal springs can widen a hot runner operating window by 100C. They also protect hot runner components in the event of system overheating. Husky hot halves fitted with UltraSeal springs are guaranteed not to leak in the pocket area for a period of 37 months from initial production.
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