Meaning
Engineered manipulation of the flow channels within a runner system alters the temperature and shear distribution of molten plastic. This meltflipper technology rotates the melt stream at runner splits to ensure that the hotter, less viscous polymer is distributed evenly to all cavities. The method is used to eliminate rheological imbalances in multi-cavity injection moulds.
Flow Manipulation
Traditional runners naturally split the high-shear boundary layers unevenly, leading to temperature differences between cavities. By utilizing meltflipper technology, the melt stream is rotated so that the high-shear material is centered in the flow. This repositioning distributes the heat and viscosity evenly across the runner branches.
Cavity Balance
Multi-cavity tools suffer from uneven filling, weight variation, and inconsistent dimensions when some cavities receive hotter plastic than others. The application of meltflipper technology balances the flow, ensuring that all cavities fill and pack under identical conditions. This balance improves the dimensional stability of the moulded parts.
Production Benefit
Moulding operations achieve higher yield and lower cycle times by eliminating cavity-to-cavity variation. Process engineers can run the tool at lower injection pressures and temperatures because the flow is naturally balanced. This reduction in stress minimizes part warpage and extends the service life of both the mould and the injection machine.
It also allows for a wider processing window, which accommodates slight variations in virgin resin batches without causing part defects.
