How To Make A Rear Injection Molding
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1 Thermoplastic Film Adhesives For Rear Injection Molding 8th Annual SPE Automotive Composites Conference & Exhibition September 16-18, 2008
2 A Part Of The Collano Group
3 Collano Milestones
4 Presentation Overview 1. History Of Rear Injection Molding 2. Today's Technology For Metal Surfaces 3. Possible Disadvantages 4. Innovative Features (Film) 5. Process Steps
5 Presentation Overview Cont. 6. Cross Section / Processing Profile (Today) 7. Cross Section / Processing Profile (Future) 8. Primer Issues 9. Outlook
6 History Of Rear Injection Molding - Plastic Parts (Textile - Fabric / Nonwovens) - Surface Improvement / Better Finishing - Wood, Foils (PVC, TPO, ABS, PC) Metal - Galvanize (Chromizing). High Waste, Up To 40%
7 History Of Rear Injection Molding Cont. - Lacquer - Transparent And Flexible For 3D Forming Normally Melamine, Acrylic, Epoxy, PUR Printing Gravure or Screen Printing - Design Issues - Bonding Technology
8 Today's Technology For Metal Surfaces - Metal (e.g. Al, Cu / Stainless Steel) - Powder Coatings - Spraying (3D Parts, Expensive) - Coil Coating (Surface Finishing) Coating Done At Metal Producer - Metal Foils - Metalized Films (Very Expensive)
9 Possible Disadvantages - Complicated Technology / Application - Various Process Steps (Low Flexibility) - High Costs In Buildings, Machinery, Staff - Complexibility (Design, Logistics, Production)
10 Possible Disadvantages Cont. - Environment / Health Concerns (Spraying) - Recycling - Fire Hazard Aspects (Regulatory Compliance, Insurance, Appropriate Equipment, Structural Measures)
11 Innovative Features (Film) - Combination With A Variety Of Substrates Textiles / Nonwovens / Plastics / Metal / Rubber - Adhesive Film (Single Layer) Direct Application To Part
12 Innovative Features (Film) Cont. - Adhesive Film (Multi Layer) Direct Application / Pre-Applied Application - Multi Layer Film Production (Up To 5 Films) ACP (Aluminum Covered Part) Hybrid Technology
13 Process Steps Today LOGISTIC PART / PRIMER ADHESIVE STORAGE / AGING COVER (METAL / PRIMER) PRESS FORMING Future COVER (METAL) MULTI LAYER FILM INJECTION COMPOUND
14 Cross Section / Processing Profile (Today) Lacquer (Mel., Acry., Epoxy, PUR) Press Forming Metal Cover (Al) Primer Storage / Aging Adhesive Nonwovens (Adhesion Promoter) Part (ABS / PC, PP) Logistic Lacquer (Mel., Acry., Epoxy, PUR) Press Forming Metal Cover (Al) Single Or Multi Layer Film Nonwovens (Plain Or Resin Coated) Part (ABS / PC, PP) Logistic
15 Cross Section / Processing Profile (Future) Lacquer (Mel., Acry., Epoxy, PUR) Rear Injection Molding Multi Layer Film Pre-Applied Application Metal Cover
16 Primer Issues - Solvent Based Products (Phenolics / Melamines) - Expensive - Smell And Emission (Formaldehyde) - Applied With Knife (Variances In Coat Weight And Possible Cluster Forming. Consequence Varying Adhesion) - Tendency To Blister When Being Applied
17 Primer Issues Cont. - Application In A Clean Room (Dust And Moisture Free) - Long Drying Times - Heat Resistance To Low (Test Hours / 100 C). At 70 C Emission - When Exposed To Pressure And Or Heat Adhesion Failure
18 Outlook - Cost (Good ROI) - Logistic (Parts) Benefits - Specialized As Well As Mass Production - Easy Production / Better Control / Lower Reject Rate / Higher Yield - Low Capital Cost - Wide Use Of Substrates And Plastics (e.g. PA, ABS, ABS/PC, PP, PC)
19 Outlook Cont. - Complex Shapes And Structures Possible - Design / Design Features / Individuality / Exclusivity - Environmental Process (No Solvents / Hazardous Substances / Recycable)
20 Your Value - New And Safe Technology - High End Components - Simple Process - Good Value - Satisfied Customers - New Possibilities / Markets
21 Embossing (Molding Tool) Picture 1 (Pictures 1-3 IWK Rapperswil/Switzerland - Institut für Werkzeugtechnik und Kunststoffverarbeitung). Structure of Al surface is shaped directly into tool (incl. clips). Either with a structured tool surface or substrate transmitters (Textiles/Nonwovens) to Al backside.
22 Crimping Technology (Emblem) Picture 2 Al stamped into shape of the part and secured on the plastic by crimping. Distortion of the Al sheet is difficult. Metal films are prone to breakage and tend to tear in deep drawn angles and edges due to their low elongation values. Single process steps are cost intensive, require high production and energy input.
23 Side Body Part And Door Sill Picture 3
24 Thank you for your attention! nolax Automotive Switzerland, Phone / william.asmann@nolax.com nolax Automotive - USA, Phone
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Training Objective After watching the program and reviewing this printed material, the viewer will become familiar with the variety, design, and productive use of plastic injection molds. Mold components
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1 How are spot welds located on the underside of an apron? A. Heat the undercoat with a torch. B. Visually inspects with a trouble light. C. Grind the surface with an angle grinder. D. Clean factory seams