the next generation of multi-component moulding · 2014. 11. 17. · (multi-component technology)...
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Oslo, Norway 22 - 23.06.2010 Jochen Mitzler
The next generation of multi-component mouldingSkinForm, X-Form, CoverForm
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Injection molding
Reaction technology
Extrusion
Your system... is out of one handOne supplier - KraussMaffei – Simple integration
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What is SkinForm ?
SkinForm ®
A system solution from different areas of expertise
Injection Moulding PUR- Moulding
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Scratch resistanceScratch resistance
Soft touchSoft touch
HighHigh --quality quality
leather propertiesleather properties
Enhancing Enhancing thinthin -- wall partswall parts
No grain
No grain warpage
warpage
The PUR surface makes the difference…SkinForm potentials
The PUR surface makes the difference…SkinForm potentials
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Fakuma 2005Micro Colour MeteringSkinForm
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Softtouch, scratch resistance and best optic and hap tic …SkinForm applications
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One shot door panel with 4 different surface materi als …Application sample automotive
Application:
• Door panel – K2007
• PC / ABS with 3 different PUR Skin materials
Innovation:
• Combination of injection moulding and PUR technology
• Part transfer with Spin-Unit
• Complex automation cell
Value:
• Part with four different surfaces
• Partial softtouch and thin overmolding
• Well directed material distribution (Skin material saving)
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Bildbereich
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SkinForm - cost advantage thru one shot processApplications for high grade surfaces, paints, flexible foam combinations, acoustic
and insulating properties
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The PUR surface makes the difference…SkinForm potentials
The PUR surface makes the difference…SkinForm potentialsUpper Upper doordoor trimtrim
Arm Arm restsrests
Paint Paint covercover
II--panelpanel
HandlesHandles
MiddleMiddle consoleconsole
DecorativeDecorativepartsparts
Airbag Airbag covercover
Seat Seat coverscovers
33--D D coverscovers
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Structural parts• PP + glass fiber
Vibration damping element
• TPU-X
• All in one
K 1998 K 2001 K 2004 K 2007
10 years of innovation and technology competences …K-Highlights of IMC technology
Exterior part• ABS+glass fiber
• Foil + cleanroom
Armrest• PP + Talkum
History of IMC (Injection Molding Compounder)
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X-Form process for new hard-soft partsExhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
1998 2000 K 2007
Metal-Rubber composites:
- increase assembly costs
- small tolerances
- pretreatment of metal part (e.g. primer)
- special rubber recipe
Thermoplastic-Rubber composites:
-Multinject Technology
-Thermal separation in mold
-Inmould-Assembly of e.g. seals
-Hot-runner / cold runner technology
-First time introduced by KraussMaffei at K1998
Per
form
ance
-/ p
rice
rela
tion
Drosselklappenventil
Bildquelle:
Vorwerk Autotec GmbH & Co. KG, Wuppertal, Deutschland
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X-Form process for new hard-soft partsExhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
1998 2000 K 2007
Metal-Rubber composites:
- increase assembly costs
- small tolerances
- pretreatment of metal part (e.g. primer)
- special rubber recipe
Thermoplastic-Rubber composites:
-Multinject Technology
-Thermal separation in mold
-Inmould-Assembly of e.g. seals
-Hot-runner / cold runner technology
-First time introduced by KraussMaffei at K1998
X-Form process for
Thermoplastic-TPU-X composites
-cross-linking thermoplastic TPU with rubber behavior
- Multinject mold technology
- No hot-cold separation in tool
- No vulcanization or post tempering process necessary
- Thermoplastic melting and filling process
Per
form
ance
-/ p
rice
rela
tion
Drosselklappenventil
Bildquelle:
Vorwerk Autotec GmbH & Co. KG, Wuppertal, Deutschland
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Application: Vibration-Damping ElementExhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
Main carrier: Ultramid CR -PA 66 GF30
Vibration damping: Elastollan® TPU-X
Sleeve: Ultramid CR -PA 66 GF30
Round seal: Elastollan®
TPU-X
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Mold concept: 4 station turn-tableExhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
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Special „Laser-cused“ cores with conture water channelsExhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
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X-Form process: continues and discontinues in on IM M Exhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
ElastollanTPU
Liquid cross-link agent
Additive
Part with TPU-X properties
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All in One – IMC, Multinject, turn-table, compact aut omation…X-Form solution on CX machine base
2. Injection unit in L-postion
Cooling station
Integrated turn-tableAutomation integratedin machine housing
IMC-Technologie forreactive compounding
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Demolding within IMM
Demolding in
separate housing- Across machine axis
Demolding in separate
housing- Operator side
20 to 40% of space saving ... Two platen benefitExhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
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Excellent bonding behaviour to PA66 (Ultramid) Exhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
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Process chain: Rubber-Metal-Composites
Process chain: Thermoplast / TPU-X Composites (X-For m)
Comparison of process and production chain for:Exhibit KM 300 IMC with SP700 L-Bolt-on for TPU - X
Pretreat-ment of
materials (e.g.
drying)
Production of metal part
Transpor-tation
Cleaning / Priming the metal part
Transpor-tation
Production of rubber
blend
Vulcanization Finished part
Melting / direct part production
(multi-component technology)
Finished part
Tolerances, assembly, QA cost, logistics costc, man ufacturing coordination, cross-company, etc.
▶Reduced quality and increased production costs
▶increased Quality and reduced production costs
Advantages of Injection molding
480 sec
70 sec
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Function integration for vibration damping – multi-c omponentApplication sample automotive
Application:
• Vibration damping element (PA66/GF 30 + TPU-X)
Innovation:
• Cross reaction process on IMC for TPU-X
• 2 Component – integrated functions and assembly process
• Cycle time reduction with 4 station turn-table
Value:
• Thermoplastic flow and processing of TPU-X
• TPU-X with rubber properties
• Up to 6 times fast than rubber processing
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Moulding and coating in one processCombination of different areas of expertise
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Moulding and coating in one processCombination of different areas of expertise
CoverForm
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Protective coating for PMMA in one step processDefinition of CoverForm
• Applying a protective, scratch-proof layer to PMMA (Plexiglas®)
• Thin coating layers possible
(< 20 µm)
• Use of acrylic-based lacquer system
• Unique development cooperation of Evonik Industries and KraussMaffei
Value:
• Cost advantage process in one step
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Kooperation ProzessSystem Materialien Technikum
� PLEXIGLAS® cf einspritzen� Prägen und Abkühlen� Kavität expandieren� Reaktivlösung einspritzen� Prägen und Heizen� Werkzeug öffnen / Entnahme� UV-Härtung
CoverForm® Prozess
Prozess
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Kooperation ProzessSystem Materialien Technikum
CoverForm® Prozess
Prozess
� PLEXIGLAS ® cf einspritzen� Prägen und Abkühlen� Kavität expandieren
Reaktivlösung einspritzen� Prägen und Heizen� Werkzeug öffnen / Entnahme� UV-Härtung
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Kooperation ProzessSystem Materialien Technikum
CoverForm® Prozess
Prozess
� PLEXIGLAS® cf einspritzen� Prägen und Abkühlen� Kavität expandieren
Reaktivlösung einspritzen� Prägen und Heizen� Werkzeug öffnen / Entnahme� UV-Härtung
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Kooperation ProzessSystem Materialien Technikum
CoverForm® Prozess
Prozess
� PLEXIGLAS® cf einspritzen� Prägen und Abkühlen� Kavität expandieren
Reaktivlösung einspritzen� Prägen und Heizen� Werkzeug öffnen / Entnahme� UV-Härtung
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Kooperation ProzessSystem Materialien Technikum
CoverForm® Prozess
Prozess
� PLEXIGLAS® cf einspritzen� Prägen und Abkühlen� Kavität expandieren
Reaktivlösung einspritzen� Prägen und Heizen� Werkzeug öffnen / Entnahme� UV-Härtung
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Kooperation ProzessSystem Materialien Technikum
CoverForm® Prozess
Prozess
� PLEXIGLAS® cf einspritzen� Prägen und Abkühlen� Kavität expandieren
Reaktivlösung einspritzen� Prägen und Heizen� Werkzeug öffnen / Entnahme� UV-Härtung
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Kooperation ProzessSystem Materialien Technikum
CoverForm® Prozess
Prozess
� PLEXIGLAS® cf einspritzen� Prägen und Abkühlen� Kavität expandieren
Reaktivlösung einspritzen� Prägen und Heizen� Werkzeug öffnen / Entnahme� UV-Härtung
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The next multi-component generation PMMA + lacquer Application sample CoverForm
Application:
• Cover (PMMA) with foil + coating
Innovation:
• New lacquer injection unit
• Dynamic mold heating
• Clean room concept for injection moulding
Value:
• Scratch resistance surface
• Compact production system incl. automation
• Cost advantage thru one shot process
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Oslo, Norway 22 - 23.06.2010 Jochen Mitzler
The next generation of multi-component mouldingSkinForm, X-Form, CoverForm