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Injection moulding and CompositesExpertise and Innovation
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Innovation
Overview of Heat&Cool technologies
ALPLASTICSStéphane DESSORS 09/07/2013
Contents
PEP presentation
Why do we have to use Heat&Cool technologies ?
Convection
Radiation
Conduction
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Conduction
Induction
Conformal cooling
Page /2 / 65
1. PEP
presentation
2. Why do we
have to use
Heat&Cool
technologies
3. Convection
4. Radiation
5. Conduction
6. Induction
7. Conformal
cooling
PEP presentation
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIEPage /3 / 65
KEY WORDS
Technical and Innovation Centre in Plastics and compositesAssociation Act 1901 – founded in 1989Expert in thermoplastics injectionExpert in compositesApproved Crédit Impôt Recherche (CIR)Certified ISO 9001 - V2008
Goal : Improvement of the competitivity of national industry thanks to innovation
INJECTION MOULDING and COMPOSITES EXPERTISE
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
and collaborative platforms.
Strategy : Mutualized research.Platforms.
75 employees (researchers, engineers, technicians)
Annual sales 2012 : 8 M€ (including COMPOSITEC)50 % Research & Developpment (contract or collaborative)50 % business services
Year Employees Services Turnover
2007 45 1,9 M € 4,2 M €
2008 50 2,4 M € 4,8 M €
2009 46 1,8 M € 4,6 M €
2010 48 2,6 M € 5,9 M €
2011 55 3 M € 6,3 M €
2012 55 3,5 M € 6,7 M €
Page /4 / 65
5 BUSINESS UNITS
KEY WORDSINJECTION MOULDING and COMPOSITES
EXPERTISE
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
5 R&D axisAdvanced toolsHybrid productsOptimal designPolymers recyclingMicrosystems on plastic
Page /5 / 65
CUSTOMERS &
MARKETS
30%
5%
22%
MARKET SHARE
AUTOMOTIVE
AERONAUTIC / ARMY
MEDICAL
PACKAGING
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
20%10%
8%PACKAGING
CONNECTIC
OTHERS
Page /6 / 65
NETWORK&
PARTNERS
PEP in the heart of a European network :
French partners :
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
European partners : R&D centres in plastic and tooling partners
Protection of innovation :
PEP files patents every year
Page /7 / 65
BU Tools & Processes
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /8 / 65
EQUIPMENTSBU Tools & Processes
PLAteforme d’INNovation Outillage
11 injection moulding machines from 15t to 2200t
Technological solutions :• Injection of multi materials up to 1000T• LSR injection (mono or bi material)• Injection sandwich• Injection compression
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
• Injection compression• Heat&Cool (ROCTOOL, GWK…)• Injection with gas• Replication of micro and nano features
2 machines for laser fusion of metal powders1 HSM 5 axisPrograms of research and innovationIn partnership with CETIM
Platinno : L’Europe s’engage en Rhône-Alpes avec le FEDER
Page /9 / 65
Technologies :
EQUIPMENTSBU Tools & Processes
SMC / BMC compression mouldingContinuous fibre reinforced thermoplastic composites thermo compression
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Moyens :
50T compression press400T compression pressInfrared oven (T° up to 400°C -(plies dimensions up to 1000 x 1000)FRTP thermo compression mouldsPlate moulds (170 x170 et 500 x 500) equipped with in-mould sensors (pressure, temperature, heat flow)« Reactivity cell » for in-situ cure monitoring
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KNOWLEDGE
Services proposed by the BU POA team of 20 engineers and technicians :
Injection trials and tuning phase of injection tools :• Optimization of cycle times• Pre-serial parts
Expertise of unstabilized processInstrumentation and Process control (press, tools, peripheral equipments)Design and realization of metallic blocks made by laser sintering
BU Tools & Processes
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Design and realization of metallic blocks made by laser sintering technology (thermal optimization of the mould)
R&D programs : Thermal optimization of the moulds (conformal cooling, Heat&Cool, induction, etc.)Integration of functionalities in the tools (decoration, assembling, etc.)Surface treatments of the cavitiesInstrumentation of the tools
Page /11 / 65
Focus :Conformal Cooling
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
1 team with 8 engineers and technicians dedicated to thermal optimization
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CONFORMALCOOLINGFocus : Conformal cooling
Goals :Reduction of cycle timesReduction of the tuning phase schedule (homogeneous temperature)Improvement of the quality of the parts
Technology :Laser used for the fusion of metallic powders (particle size 30µ)Produced layer by layer (0.04 mm)
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Characteristics of Maraging steel ( ≈ Z38CDV5) :Hardness : 37 to 54 HRC after hardening.Density : 99,8 %
Methodology :1. CAD – Thermal studies with SIGMA 3D : optimal design of the channels2. Fluidic studies with FLOWORKS3. Laser sintering technology to make metallic blocks4. Finishing with HSM 5 axis5. Validation of the flow rates and thermal properties6. Thermal treatment (hardening)
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M COOLM COOL
Optimization process with MCOOL® (PEP Patent) :
– Definition of the optimal surface for mould regulation
– 2 goals :
• Plastic material must be frozen according the cycle time defined by MOLDTHERM® (PEP patent)
• Homogeneous cooling
Design of the cooling channels:
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Optimized regulationsurface
Design of the cooling channels:
Consideration of the volume of the mould and kinematicsConsideration of hydraulic properties (pressure losses)
Optimized regulationStandard regulation
Page /14 / 65
Business Unit Design & Simulation
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /15 / 65
EQUIPMENTSBU Design & Simulation
A team with 12 Doctors and engineers,several softwares dedicated to parts and moulds desi gn
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
DESIGN
- CATIA
- SOLIDWORKS
DESIGN
- CATIA
- SOLIDWORKS
RHEOLOGY
- MOLDFLOW
- SIGMA 3D
RHEOLOGY
- MOLDFLOW
- SIGMA 3D
OPTIMIZATION
- ANSYS
- MODEFRONTIER
- OPTISTRUCT
OPTIMIZATION
- ANSYS
- MODEFRONTIER
- OPTISTRUCT
Page /16 / 65
SERVICESBU Design & Simulation
Pré-studyPré-study
Preliminary designPreliminary design
Part/Process designPart/Process design
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Part/Process designPart/Process design
Support for the tools and equipments manufacturingSupport for the tools and
equipments manufacturing
Tunings of production facilitiesTunings of production facilities
Transfer of the production facilities
Transfer of the production facilities
Page /17 / 65
BU Materials
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /18 / 65
EQUIPMENTS
Laboratory analysis and characterisation: Rheological (capillary rheometer, MFI, viscosity in solution)Mechanical (dynamometer, hardness tester, DMA…)Physico-chemical ( µFTIR, SEM,..)Aging (thermal, UV, climatic)Thermal (HDT, VICAT, DSC, ATG)Optical (microscope, brightness and colour measurements..)Flammability (FMVSS, UL94)Preparation of samples
BU Matériaux
• Pellets• Samples• Parts and products
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Preparation of samplesSelf Approval RENAULT
Twin-screw compounder
Injection moulds with sensors (15)
A team of 9 experts : polymers, composites, characterisation, biomaterials, compounding
Materials database : RAPRA, Prospector Pro
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KNOWLEDGE
Services from BU MAT
Choice of materials :Research or substitution of materialsComparison of materialsValidation of specificationsBiopolymers
Testing, analysis or characterisations
BU Matériaux
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Testing, analysis or characterisations
Production control (composites)
Establishment of data sheets
Quality control and material expertise
Formulation – compounding – injection – characterisation – analysis Polymer recycling, co-productLoad integration, reinforcements
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BU Plastronics :Smart Plastic Products
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Le PEP est membre du GIXEL
Page /21 / 65
EQUIPMENTS
Equipments in PEP :Laser activation with LPKF-LDS Microline 3DPrototype plating line for electroless copper, nickel and goldCharacterization, tests and qualification: metrology and X-rays fluorescence for thickness control, other propertiesA team of 7 experts : design, injection moulding, electronics and MID (Moulded Interconnect Device)
BU Plastronics
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Technological partners : LPKF, Dow, RTP, Häcker, Samaro, Acxys, ACP, HSG-IMAT, CEA, CSEM, MIND, IMECKey partnerships and European network: « 3D-MID » et « 4M »
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KNOWLEDGE
Micro- and nano- replication of functional features :
Pilot injection moulding platform with all required facilities for micro-/nano- replication
100% electrical injection moulding machine, 200T, bi-materialCompression moduleVacuum in the cavityHeat&Cool technologies to heat the cavities : Roctool, GWKOn line Plasma surface activation : AcxysOn line CO2 cleaning : ACP
BU Plastronics
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
On line CO2 cleaning : ACPOn line metrology control : ZeissAll the tasks in the injection cell are automatic thanks to a 6 axes robot from Stäubli
Exemples of functionalities proposed by micro- nano- r eplication on plastic parts:
Optic, embellishment and security / anti counterfeitingMicro fluidic : channels, filters, valves, anti-adhesion, diaphragmMicro mecanic / MEMS
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KNOWLEDGE
Design and realization of 3D-MID (Moulded Interconnect Devices) :
Goals :Adding functionalities to plastic parts (electrical connexions)Miniaturization and reduction of the number of components3D designReduction of the weightReliability of the function
BU Plastronics
Cré
dit :
Cas
sidi
an,
Fic
osa,
MIN
D, T
BI,
Rad
iall
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Functions :Sensors, antenna, 3D wiring, connectors,lighting/signalisation, shielding, heat dissipation
Cré
dit :
Cas
sidi
an,
Page /24 / 65
LDS®-LPKFFocus
Thermoplastic Injection
Laser activation Chemical copper
Chemical gold deposition
Chemical nickel deposition
Chips assembly (CMS, flip-chip)
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Injection copper deposition
depositiondeposition
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LDS®-LPKFFocus
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Without MID With MIDSource kromberg & schubert
Page /26 / 65
LDS®-LPKFMID examples
Source Bosch
Source TBI - ABAXX
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Source Harting
Source Panasonic
Page /27 / 65
Technological Watch and Competitive Intelligence
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Competitive Intelligence Centre
Page /28 / 65
EQUIPMENTS
Specific documentation centre for Plastic industry
Access to data bases :• RAPRA• Thomson Innovation • Dialog (more than 500 data bases)• SPE
Technological watch and competitive intelligence centre
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
• SPE
Specialist of the Technical and Scientific Information
Plasturgienet• Data base with more than 6 000 references• Free access codes• www.plasturgienet.com
Page /29 / 65
Why do we
have to use
1. PEP
presentation
2. Why do we
have to use
Heat&Cool
technologies
3. Convection
4. Radiation
5. Conduction
6. Induction
7. Conformal
cooling
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
have to use
Heat&Cool
technologies ?
Page /30 / 65
HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Heating the cavities to improve the filling
Cooling the mould to decrease the cooling time
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /31 / 65
HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Why do we inject in a warm mould ?
Filling length
Brightness / Darkness
Welding linesreduced
Better replication (grain,micro- and
nano- features…)
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Thin walls
Filling length
Better aspectwith materialsincluding fibres
Better holdingpressure (no sink mark)
Reduction ofinternal stress
(dimensional stability)
Reduction of thefrozen skin (mechanical
properties)
Page /32 / 65
HEAT & COOLWhy do we have to use Heat&Cool technologies ?
Reduction of the frozen layer
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cage system ® de RocTool
Simulation of the frozen layer without induction (left) and with induction (right)
Page /33 / 65
HEAT & COOLWhy do we have to use Heat&Cool technologies ?
Reduction of internal stress in the part
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cage system ® de RocTool
Pictures made with polarized lens without induction (left) and with induction (right)
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HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Brightness of the part in polished area
Without Cage system
With Cage system
Ra value for 5 different polymers
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cage system ® de RocTool
Brightness of the part in polished area
Brightness of the part in grained area
Rz value for 5 different polymers
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HEAT & COOLWhy do we have to use Heat&Cool technologies ?
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Pressure measurements in the cavity, in 3 areas, with and
without Cage system
Cage system ® de RocTool
Page /36 / 65
HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Fibres marks removed thanks to Heat&Cool
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cage system ® de RocTool
Parts injected with PP loaded with long glass fibres, without induction (left) and
with induction (right)
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HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Dimensional stability highly improved
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cage system ® de RocTool
Dimensions deviations from nominal size
(in percentage), without induction (blue)
and with induction (red)
Deviations of the dimensions due to
thermal cycles (in percentage), without
induction (pink) and with induction (red)
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HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Dimensional stability highly improved
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cage system ® de RocTool
Standard deviation of the process in percentage, without induction
(blue) and with induction (red), for ABS (left) and for PEHD (right)
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HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Improvement of the mechanical properties
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cage system ® de RocTool
Charpy test for several polymers, with and without induction, in the
longitudinal direction (blue) or transverse direction (red)
Page /40 / 65
HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Improvement of the mechanical properties
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cage system ® de RocTool
Pulling module for several polymers, with and without induction, in
the longitudinal direction (blue) or transverse direction (red)
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HEAT & COOL
Why do we have to use Heat&Cool technologies ?
Technology required for micro
and nano replication
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Influence of mould temperature
Page /42 / 65
HEAT & COOL
Convection
4 different kind of technologies :
Convection
Heating with water or oil
Heating with steam
Heating with pressurized water
Heating with hot air
Radiation
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Radiation
Conduction
Induction
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HEAT & COOL
Convection
Heating technologies based on convection
phenomenon
Thermoregulation with water : < 95°C
Thermoregulation with pressurized water : < 200°C
Thermoregulation with oil : < 350°C
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /44 / 65
HEAT & COOL
Convection
Variotherm
2 fluids are required (1 hot fluid and 1 cold fluid)
Either 1 channel or 2 seperate channels
Electro valve to switch from the heating to the cooling, or
from the cooling to the heating
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /45 / 65
HEAT & COOL
Convection
Variotherm BFMOLDTM from Wittmann/Battenfeld
(developed by Kunststoff Institut from Ludenscheid)
Metallic balls are placed behind the surface of the cavity
Balls are able to support high pressure and reduce the volume of steel
� better efficiency
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
� better efficiency
Page /46 / 65
HEAT & COOL
Convection
Heating with steam
RHCM: Rapid Heat Cycle Molding
(Ono Sangyo Co and Sabic Innovative Plastics)
RTCTM: Rapid Temperature Cycling
(distributed by F.I.T. in Oyonnax)
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /47 / 65
HEAT & COOL
Convection
Heating with steam
Advantages:
Same channels in the mould for
heating and cooling
Steam is recycled
Drawbacks:
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Drawbacks:
Maximal mould temperature is
180°C
Optimized cooling is highly
recommended (conformal
cooling)
Page /48 / 65
HEAT & COOL
Convection
High pressurized water
Advantages:
Same channels in the mould for heating and cooling, very
easy to set up
Possibility to use it as curative solution
Low energy consumption
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Drawbacks:
Maximal mould temperature is 190°C
Optimized cooling is highly recommended (conformal cooling)
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HEAT & COOL
Radiation
4 different kind of technologies :
Convection
Radiation
Infra-Red radiation
Heating with electrical or gas supply
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Heating with electrical or gas supply
Conduction
Induction
Page /50 / 65
HEAT & COOL
Radiation
Infra-Red radiations
Wavelength: 800 to 3000 nm
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /51 / 65
HEAT & COOL
Conduction
4 different kind of technologies :
Convection
Radiation
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Conduction
Quick heating with mice or ceramic components
Heating with electrical cartridges
Induction
Page /52 / 65
HEAT & COOL
Conduction
Strato conception + conformal cooling
Cavities are made with 3 metallic blocks
Heating component is placed between the 2 superior plates
Conformed channels are drilled in the inferior plate
Assembling of the blocks with a brazing process
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Only 1 screen to manage the heating and the cooling
Page /53 / 65
HEAT & COOL
Conduction
Strato conception + conformal cooling
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /54 / 65
HEAT & COOL
Induction
4 different kind of technologies :
Convection
Radiation
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Conduction
Induction
External induction
Induction integrated in the mould
• Cage system®
• 3iTech®
Page /55 / 65
HEAT & COOL
Induction
RTCTM IHC from GIWW
Inductor coil fixed on a slide under the mould
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /56 / 65
HEAT & COOL
Induction
Inductor coil fixed on the handler
Almost no specifications for the mould
Easy set up in the workshop
Possibility to use it as a curative solution
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /57 / 65
HEAT & COOL
Induction
Cage system® from RocTool
Electrical loops around the mould (gap of several millimeters)
Cavity heating on the surface (Joule effect on both sides of the
mould)
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Example of cavity heating
for a 500x600mm part:
between 6°C/s and 10°C/S
Page /58 / 65
HEAT & COOL
Induction
Cage system® from RocTool
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /59 / 65
HEAT & COOL
Induction
3iTech® from RocTool
Inductor coils integrated in the cavity block
Possibility to heat the cavity even when the mould is closed
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /60 / 65
HEAT & COOL
Induction
3iTech ® de RocTool
3iTech® from RocTool
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /61 / 65
HEAT & COOL
Cooling
Conformal cooling
Laser sintering technology with metallic powders
highly recommended to combine this technology with a heating solution:
to have better efficiency
to reduce cycle times
to improve the quality of the parts
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
to improve the quality of the parts
Page /62 / 65
HEAT & COOL
Cooling
Refroidissement au gaz carbonique
Cooling with CO2
Technology based on CO2 change of phase (liquid ↔ gas)
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /63 / 65
HEAT & COOL
Conclusion
Best results are achieved when Heating and cooling technologies are
combined
Lots of parameters must be considered to evaluate what is the best solution:
Temperature that has to be reached
Cycle time and batch size
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Cycle time and batch size
Design of the part
Part price / Investments
PEP’s experience is helpful if you have to optimize a process with a
Heat&Cool technology
Page /64 / 65
HEAT & COOL
Conclusion
Thank you
Feel free to ask questions
EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE
Feel free to ask questions
Stéphane DESSORS
+33 (0) 4 74 81 92 80Page /65 / 65