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8/18/2019 Innovative Injection Molding Process.pdf
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BASIC-TRAINING 2003
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Table of content
è The Multiple Component Technologies
è The Sandwich-Technologies
è The Injection Welding-Technologies
è Summary: Why Multiple-Component-Technologies?
è What does EMS-Grivory offer?
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The Multiple Component Technologies
Sandwich Injection Moulding
Coinjection Monosandwich GIT WIT
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Injection Welding
Injection Welding(2C-IM)
Biinjection Push-Pull-IM
The Multiple Component Technologies
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Sandwich-Injection Moulding
Different Properties in one Part
v i r g i n
m a t e
r i a l
u n r e i n f o r c e d m a t e r i a l
high performance polymer
(flame retardant, weather-, heat-, chemical resistant)
Gas (GIT)
Water (WIT)regrind
foam
low cost
reinforced
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Coinjection
Two melts will be injected into the cavity through one gate
one after the other.
1
2
1. Injection of the skin-material with unit 12. Injection of the core-material with unit 2
Skin/Core-structure
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1. Metering of the core-material with the injection unit2. Metering of the skin-material with the extruder 3. Injection of the two materials in one step
Skin/Core-structure
Two materials will be injected with one injection unit, through
one gate into the cavity.
Mono-Sandwich
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Gas-Injection-Technology
Portable compression station
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Idea of the Gas Injection Technology
Problem with the conventionalinjection moulding
Wall-thicknesses of 3-4 mm can be moulded
without problems, higher wall-thicknesses
results in:
Possible Solution: Use of the Gas-Injection-Technology
Principle: Gas (usually nitrogen) will be injected into the part,
replaces the melt in the core and creates an hollow space.
è sink marksè long cycle time
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GIT - Technologies
Standard - Gas Injection-Technology
è Partial filling with melt
è Injection of gas and complete filling of the cavity
è Hold-on pressure phase with gas
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Variant:
è Volumetric filling of the cavity with melt
è short hold-on phase and injection of gas
è Displacement of the melt with gasè Hold-on pressure phase with gas
Ê Melt back into the screw
GIT - Technologies
GIT-Special Processes (Blow back process)
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Ì Retraction of a core
GIT - Technologies
GIT-Special Processes (Blow out process)
Ë Displacement of the melt into an overflow cavity
Variant:
è Volumetric filling of the cavity with melt
è short hold-on phase and injection of gas
è Displacement of the melt with gasè Hold-on pressure phase with gas
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Handle
Grilon BS/2
Automotive door-handleGrivory GV-5H
Backflow of the melt into the screw
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Backflow of the melt into the screw
Motorcycle-gear-lever Grivory GV-5H
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Displacement of the melt into an overflow cavity
Motorcycle-carrier
Grilon PVS-5H
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Advantages of the Gas Injection Technique
production of parts with high wall-thicknessesand/or material accumulations
è increased strength and stiffness at lower or
equal part weight
reduction of weight up to 50%
è lowering of the material costs
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Advantages of the Gas Injection Technique
reduction of the cooling-/cycle time up to 50%
lower clamping force
è lowering of the machine costs
no/less sink marks
parts with less distortion
è improved part quality
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Development started at IKV Aachen in 1999
Target:
Reduction of cycle time for applications like:
– handles
– armrests
– media ducts
Water injection technology (WIT)
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Process Versions (equal procedure like GIT)
Short-Shot Process – Partial filling of cavity
Full Shot Process
– Filling into additional cavity
– melt is pushed back into screw
– core is pulled back
WIT-Process
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Short shot process
High speed shooting of the filling process in a transparent tool
water
WIT-process of IKV
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Transparent-Tool
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è blowing out the water with compressed air
è use of water containing blowing agents (e.g.
carbonic acid)
è evaporation of water after pressure relief
(water temperature >100°C; residual water)
Water recovery
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è shorter cycle times (40% versus GIT)
è smaller wall thickness
è wall thickness is constant⇒ less warpage
è larger part diameters
è water is cheaper than gas and incompressible
è smoother inner surfaces
Advantages of WIT compared to GIT
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è danger of splashing water when setting is
wrong
è precautions have to be taken for water removal
è not all materials are suitable (voids)
è injector marks are bigger (~ 6mm)
Disadvantages of WIT
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è no special WIT grades are available
è no own WIT equipment
è experience with GIT
è first experience done for some standard
grades
è some materials are in test
è good contact to IKV and leading machinemanufacturers
EMS Activities and Support
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Different functions and/or properties are combined
in one part.
Injection Welding
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Target: Adhesion between two materials
Hard/Soft-Applications:
è Sealings direct injectedè Soft Touch: Improving of grip feeling and
reduction of vibration
èOperation knobs
Transparent/not transparent-applications:
è overmoulding of transparent parts
Injection Welding
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Process Steps and Tool Construction
Principle of injection welding1. Injection of the preform
2. Transpose of the preform
3. Injection of the second material
Injection-/Tool Technology
Two injection moulding machines and two tools
è Transpose technology (hand or with a robot)
Injection moulding machine with two or more injection units
è Rotation-/Index-plate-/Core-puller mould
1
2
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Possible Material Combinations
Grilon (PA6) + Grilon ELX (PA6 - Elastomer)
Grilamid (PA12) + Grilamid ELY (PA12 - Elastomer)
Grilamid (PA12) + Grilamid TR (PA amorph)
Grilon/Grilamid "HM" + Thermoplastische Elastomere
HM = haftungsmodifiziert (SEBS und/oder PP/Gummilegierungen)
Grilon/Grilamid/Grivory + Polyurethan-Elastomer
Grilon PV-15H HM / PV-3H HM / PV-4H HM / PV-5H HM
Grilon T XE 3187
Grilamid XE 3168
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Hard/Soft Combination with Grilon HM
Door lock switch cover Grilon PV-3H HM + TPE (Thermoflex)
Electro plugGrilon T XE3187 + TPE (Thermoflex )
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Hard/Soft Combination with Grilon HM
Infrared key transmitter
Grilon PV-4H HM + TPE (Thermoflex)
Steering column switch for light
Grilon PV-3H HM + TPE (Thermoflex)
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Target: movable but not separable junction
Two-Component Injection Moulding
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The meltfront distribution
determines the position of theweldline.
The weldline has no definedshape.
Calculations and tests arenecessary.
High numbers of material combinations because of very good
compatibility.
Two melts will be injected into the cavity through two
different gate positions
Biinjection
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Glassfibres are oriented parallel to
the melt front (glassfibres do not
break through the matrix)
Additives and degradation products
can reduce the strength.
What is the problem?
The result is a bad weldline strength.
With ideal conditions it is possible to achieve a weldline.strength of about 40%of the tensile strength.
Weldline of Glassfibre Reinforced Materials
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2C-IM-maschine with aspecial software
Tool with two gates
Cavity
Prinziple of the Push-Pull Process (Ferromatik)
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StandardIM-maschine
SCORTEC-head withhydraulic pistons
Software and hydraulik system externalor integrated into the IM-machine
Tool with two or moregates
Cavity
Prinziple of the SCORIM-Process
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Increasing of the weldline strength up to
the level of the tensile strength.
General improvement of the properties
caused with a high orientaion of fibres
and molecular chains.
Reduction of voids and sink marks.
Results:
konv. SPR GTS
P o s i t i o n o f
w e l d l i n e
Prinziple of th Push-Pull Process (GTS)
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Standard-injection
moulding
Push-Pull process
B i n d
e naht v e r l a u f
1 mm
(Grivory GV-5H processed with the SCORIM-Process)
Glass Fibre Orientation in the Area of the Weldline
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Summary:
Why Multiple Component Technology?
we are able to:
è produce multifunctional parts.
è Combine products with different properties.
è Reduce material- and machine costs.
è Lower part price.
è Improve mechanical properties. Solve
injection moulding problems.
è Increase the product- and production security.
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è delivers proper materials.
è has experiences with the different process technologies
and EMS-CMEMIE materials
è knows advantages and disadvantages of the
technologies.
è has injection moulding machines for the different
technologies and these can be used for customer trials.
è We give support for new developments.
What does EMS-Grivory offer ?