Back Molding Technology. Decorated parts in one process step
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- Dayna Butler
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1 Decorated parts in one process step
2 Contents Introduction Overview Textile Special Processes IML 1. Introduction 2. Decoration processes - overview 3. Technology for decoration with films 4. Technology for decoration with textiles 5. Special processes for decoration 5.1 Back Molding with foamed material 5.2 Sequential injection molding 5.3 Compression injection molding 6. In Mold Labeling (IML)
3 Contents Introduction Overview Textile Special Processes IML 1. Introduction 2. Decoration processes - overview 3. Technology for decoration with films 4. Technology for decoration with textiles 5. Special processes for decoration 5.1 Back Molding with foamed material 5.2 Sequential injection molding 5.3 Compression injection molding 6. In Mold Labeling (IML)
4 Motivation Introduction Overview Textile Special Processes Increasing of profitability by: Integrated functions Saving of the following process steps, e.g. printing painting laminating high level of automation IML
5 Contents Introduction Overview Textile Special Processes IML 1. Introduction 2. Decoration processes - overview 3. Technology for decoration with films 4. Technology for decoration with textiles 5. Special processes for decoration 5.1 Back Molding with foamed material 5.2 Sequential injection molding 5.3 Compression injection molding 6. In Mold Labeling (IML)
6 Back Moulding Technology Goal and way of solution Introduction Completely decorated molding out of the injection molding machine Overview Textile Special Processes IML Back Molding of preformed printed films Back Molding of printed carrier films In Mold Decoration (IMD) Back Molding of wood veneer Back Molding of textiles In Mold Labelling (IML)
7 Decoration processes Introduction Overview Textile Special Processes IML s: In Mold Decoration (IMD) using embossing films Insert Molding (FIM) using flat or preformed films TPO s Textiles: Trimming as a separate process outside the mold In Mold Cutting (IMC) = textile cutting in the mold Wood: Veneer
8 Contents Introduction Overview Textile Special Processes IML 1. Introduction 2. Decoration processes - overview 3. Technology for decoration with films 4. Technology for decoration with textiles 5. Special processes for decoration 5.1 Back Molding with foamed material 5.2 Sequential injection molding 5.3 Compression injection molding 6. In Mold Labeling (IML)
9 Technolgy for Decoration with film IMD FIM Flat Preformed 1. In Mold Decoration - IMD 2. Insert Molding - FIM Flat film Preformed film TPO film 1. Backmolding of wood TPO Wood
10 In-Mold-Decoration (IMD) IMD FIM Flat Preformed Principle: feeding device transports decorated film in between two opened halfs of the mould Back Molding of the film Decoration relieves from the carrier film and fixes on the molding TPO Wood
11 In-Mold-Decoration (IMD) feeding device IMD FIM Flat Preformed TPO Wood Quelle/Source: Fa. Kurz
12 In-Mold-Decoration (IMD) IMD IMD-s: single decorative film endless decorative film FIM Flat Preformed TPO Wood /Vitalo/
13 In-Mold-Decoration (IMD) Principle design of the embossing film IMD FIM Flat Preformed TPO Wood Direction of back molding Decorative layer Scratch resistant layer Separation layer Carrier layer Transfer layer
14 In-Mold-Decoration (IMD) IMD Process variable normal construction construction for depth effect FIM Decorative layer Plastic Plastic Decorative layer Flat Preformed TPO Visible site Visible site Wood
15 In-Mold-Decoration (IMD) IMD FIM Flat Preformed TPO Multiple designs and functions Metallic-pigments Metallized areas Brushed areas Colour changing with temperature Hologram Special scratch resistant Shielding effect Wood
16 In-Mold-Decoration (IMD) IMD FIM Flat Preformed Applications : Automotive Telecommunication Household and electronic Cosmetics (Packaging) Hifi Leisure and sports TPO Wood
17 In-Mold-Decoration (IMD) IMD Application: Automotive Product code for cars FIM Flat Preformed TPO Wood Quelle/Source: Fa. Kurz
18 In-Mold-Decoration (IMD) IMD Application: Automotive Cover FIM Flat Preformed TPO Decorative molding Wood Quelle/Source: Fa. Kurz
19 In-Mold-Decoration (IMD) IMD Application: Automotive Cover for heater control FIM Flat Preformed TPO Wood
20 In-Mold-Decoration (IMD) IMD Application: Telecommunication Display for mobile phone FIM Flat Preformed TPO Wood
21 In-Mold-Decoration (IMD) IMD Application: Telecommunication Housing for mobile phones FIM Flat Preformed TPO Wood Quelle/Source: Fa. Kurz
22 In-Mold-Decoration (IMD) IMD Application: household /electronic Household goods FIM Flat Preformed TPO Wood Quelle/Source: Fa. Kurz
23 In-Mold-Decoration (IMD) IMD Application: household /electronic Household goods FIM Flat Preformed TPO Wood
24 In-Mold-Decoration (IMD) IMD Application: household /electronic Electronic FIM Flat Preformed TPO Wood Quelle/Source: Fa. Kurz
25 In-Mold-Decoration (IMD) IMD Application: household /electronic Cover for loud speaker FIM Flat Preformed TPO Wood Quelle/Source: Fa. Kurz
26 In-Mold-Decoration (IMD) IMD Application: Cosmetic Aesthetic packaging FIM Flat Preformed TPO Wood Quelle/Source: Fa. Kurz
27 In-Mold-Decoration (IMD) IMD FIM Flat Preformed Mold technology and accessories 2- and 4 - cavity molds possible Direct gating with hotrunner Positioning with printed brands Tolerances at the molded part up to ± 0,02 mm Closed loop control between film feeding device and optical sensor Communication between film feeding device and IMM via interface TPO Wood
28 In-Mold-Decoration (IMD) IMD FIM Flat Preformed Advantage high automation level flexible in design and fast changing of decorative surface no pre-treatment no solvents good adhesion on the substrate decorative surface is able to cover welding lines TPO Wood
29 In-Mold-Decoration (IMD) IMD FIM Flat Preformed Boundary conditions special moulds heat resistance of the film must be higher than melt temperature minimal number of pieces and timing for the production of the film depth of the decorated surface is limited radius are limited cleaning of the parts might be necessary TPO Wood
30 Insert Molding (FIM) IMD FIM Flat Preformed Principle: more thicker and rigid film (painted or printed) is inserted in the mould films are preformed or not and cutted flat and 3 dimensional parts can be molded film is part of the molded article TPO Wood
31 Insert Molding (FIM) IMD FIM Flat Preformed Main applications: automotive telecommunication medical technology white goods... TPO Wood
32 Insert Molding (FIM) flat films Application: production of a tray IMD FIM Flat Preformed TPO Wood
33 Insert Molding (FIM) flat films System technology buffer double gripper IMD mold FIM Flat separation of films Preformed TPO Wood film magazin hot stamping of the rim transport of finished parts
34 Insert Molding (FIM) flat films IMD System solution for back molding of films Video: system solution FIM Flat Preformed TPO Wood
35 Insert Molding (FIM) flat films cover for washing machine IMD FIM Flat Preformed TPO Wood Material: PMMA
36 Insert Molding (FIM) preformed films printed film preformed film precutted film Final part IMD FIM Flat Preformed TPO Wood process steps Quelle/Source: Fa. Kurz
37 Insert Molding (FIM) preformed film IMD FIM Flat Preformed Decoration of the film silk screen printing Off- set printing colouring of the film vacuum coating scratch proof coated PVD coated TPO Wood Quelle/Source: Fa. Bayer
38 Insert Molding (FIM) preformed film IMD FIM Flat Preformed Preforming if the film mechanical hydraulic thermoforming preforming during back molding high Pressure Forming (HPF) TPO Wood High Pressure Forming Quelle/Source: Fa. Bayer
39 Insert Molding (FIM) preformed film IMD FIM Flat Preformed Cutting cutting with knife for single samples steel rule cutting die depends on geometry for pilot plant production cuttiing die for mass production TPO Wood Quelle/Source: Fa. Bayer
40 Insert Molding (FIM) preformed film IMD FIM Flat Preformed TPO Insert and setting insert manual with robot setting cores in the mold ejector systems slide (clamp) pins out site the cavity vacuum electrostatic loading Wood
41 Insert Molding (FIM) preformed film IMD FIM Flat Requirements for robot high precision with servo axes suitable gripper cross head gripper turning double gripper assembling of charging element Preformed TPO Wood
42 Insert Molding (FIM) preformed film Insert of preformed films triode IMD FIM Quelle/Source: Fa. HAUG Flat Preformed TPO Wood charging generator double gripper with 3 triods filmmagazin Tranport of finished parts
43 Insert Molding (FIM) preformed film Application: cover for heater controls IMD FIM film Flat Preformed TPO Wood end product Quelle/Source: Fa. Bayer Material: PC
44 Insert Molding (FIM) preformed film Application: cover for a car IMD FIM Flat Preformed TPO Wood Material: ABS + PC/ABS Quelle/Source: Fa. Bayer
45 Insert Molding (FIM) preformed film Application: cover for a car Preformed and cutted film IMD FIM Flat Preformed TPO Wood Material: ABS + PC/ABS final part Quelle/Source: Fa. Bayer
46 Insert Molding (FIM) preformed film Application: side protector trim IMD FIM Flat Preformed TPO Wood
47 Insert Molding (FIM) preformed film Application: side protector trim IMD FIM Flat Preformed TPO Wood production cell with HM 3500 / 2280 and KUKA KR 30
48 Insert Molding (FIM) preformed film Application: side protector trim IMD clean room conditions KUKA KR30/3 FIM Flat Preformed TPO Wood precentering of film end parts remove final part insert of film
49 Insert Molding (FIM) preformed film IMD FIM Flat Preformed TPO Requirements for the film transparency suitable for printing elasticity for preforming load-bearing capacity for cutting process heat resistance shrinkage behaviour high surface quality Wood
50 Insert Molding (FIM) preformed film IMD FIM Flat Preformed Advantages fast changing of decorating multiple possibilities for decorating 3-D geometry possible no pre treatment welding lines can be covered protected printing TPO Wood
51 Insert Molding (FIM) preformed film IMD FIM Flat Preformed Boundary conditions additional process for production of film additional investment automation smaller process window cleanness (clean room conditions) TPO Wood
52 TPO - film IMD FIM Flat Preformed TPO characteristics very often surfaces like leather multi layer barrier for flow with and without foamed backing lay-up in the mold preheated application for intirior covers automotive limitation in regard of small radius (otherwise surface defects) Wood
53 TPO - film Interior cladding part with TPO-film Daimler Chrysler Vito IMD FIM Flat Preformed TPO Wood Quelle/Source: Fa. Müller, Wallau
54 TPO - film Interior cladding part with TPO-film Daimler Chrysler Vito IMD FIM Flat Preformed TPO Wood Quelle/Source: Fa. Müller, Wallau
55 TPO - film Different applications IMD FIM Flat Preformed TPO Wood Quelle/Source: Fa. Müller, Wallau
56 Backmolding of decorative wood IMD FIM Flat Preformed TPO Wood Quelle/Source: Fa. Summerer
57 Contents Introduction Overview Textile Special Processes IML 1. Introduction 2. Decoration processes - overview 3. Technology for decoration with films 4. Technology for decoration with textiles 5. Special processes for decoration 5.1 Back Molding with foamed material 5.2 Sequential injection molding 5.3 Compression injection molding 6. In Mold Labeling (IML)
58 Back Molding of textile Introduction Process: without In Mold Cutting (conventional process) Overview Precutting of textile Gripper takes the precutted textile Hand over to the mould Textile Special Processes Mold is closed Back Molding with plastic material Mold opens IML Molded part with excess length of textile is taken out Cutting of textile
59 Back Molding of textile without In Mold Cutting Introduction Precutting of textile Overview Textile Special Processes Precutting of textile from a coil IML
60 Back Molding of textile without In Mold Cutting Precutting of textile Introduction Overview Textile Special Processes IML 6- axis robot with CO 2 laser head Quelle/Source: Fa. Robot Technolgy
61 Back Molding of textile without In Mold Cutting Introduction Cover for C-column with excess length of textile Overview Insert excess length of textile Textile Special Processes IML Quelle/Source: Fa. Müller, Wallau
62 Back Molding of textile without In Mold Cutting Covers for columns VW T5 Introduction Overview Textile Special Processes IML
63 Back Molding of textile without In Mold Cutting Covers for columns VW T5 Introduction Overview Edge wrapping device Central ABB 6-axis robot Textile Special Processes Laser cutting with ABB 6-axis robor IML HM P / 7700
64 Back Molding of textile without In Mold Cutting Introduction Interior door panel VW Overview Textile Special Processes IML Quelle/Source: Fa. Müller, Wallau
65 Back Molding of textile Introduction Process: In Mold Cutting (IMC)) Overview Precutting of textile Gripper takes the precutted textile Hand over to the mold Textile Special Processes Mold is closed Back Molding with plastic material Mold is opened IML Part ready to assemble is taken out Textile cutting
66 Back Molding of textile with In Mold Cutting Introduction Production cell (UNIROB R15 with gripper) Overview Textile Special Processes HM 3500/ L Hand over of textile MouldwithIMCmore technology IML Textile cutting with laser Parts ready to assemble
67 Back Molding of textile with In Mold Cutting Introduction Process: In Mold Cutting with more material technology Overview Precutting of textile Gripper takes the precutted textile Hand over to the mold Textile Special Processes Mold is closed Back Molding with plastic material Cutting of textile in the mold IML Injection of TPE sealing Mold is closed Part ready to assemble is taken out
68 Back Molding of textile with In Mold Cutting Process Introduction Overview Precutting of textile Gripper takes the precutted textile Hand over to the mold Textile Special Processes Mold is closed Back Molding with plastic material Cutting of textile in the mold IML Injection of TPE sealing Mold is closed Part ready to assemble is taken out
69 Back Molding of textile with In Mold Cutting Introduction Precutting with laser system Overview Textile Special Processes IML high flexibility less waste
70 Back Molding of textile with In Mold Cutting Process Introduction Overview Precutting of textile Gripper takes the precutted textile Hand over to the mold Textile Special Processes Mold is closed Back Molding with plastic material Cutting of textile in the mold IML Injection of TPE sealing Mold is closed Part ready to assemble is taken out
71 Back Molding of textile with In Mold Cutting Introduction Hand over of the precutted textile to the mold Overview Textile Special Processes IML
72 Back Molding of textile with In Mold Cutting Process Introduction Overview Precutting of textile Gripper takes the precutted textile Hand over to the mold Textile Special Processes Mold is closed Back Molding with plastic material Cutting of textile in the mold IML Injection of TPE sealing Mold is closed Part ready to assemble is taken out
73 Back Molding of textile with In Mold Cutting Introduction Integration of functions Overview Textile Special Processes IML sealing of TPE
74 Back Molding of textile with In Mold Cutting Process Introduction Overview Precutting of textile Gripper takes the precutted textile Hand over to the mold Textile Special Processes Mold is closed Back Molding with plastic material Cutting of textile in the mold IML Injection of TPE sealing Mold is closed Part ready to assemble is taken out
75 Back Molding of textile with In Mold Cutting Introduction Demolding Overview Textile Special Processes IML
76 Back Molding of textile with In Mold Cutting Introduction Overview Production cell solution 1 solution 2 Textile Special Processes IML
77 Back Molding of textile with In Mold Cutting Introduction Additional functions with 6-axis robot Overview Textile Special Processes cutout IML
78 Back Molding of textile with In Mold Cutting Introduction System solution Overview Textile Video: System solution Special Processes IML
79 Back Molding of textile with In Mold Cutting Introduction System solutions with partners Overview Textile Special Processes IML
80 Back Molding of textile with In Mold Cutting Introduction In Mold Cutting Overview = advantages for the moulder Textile Special Processes saving of space safe process profitable IML
81 Back Molding of textile with In Mold Cutting Introduction Overview Future Using of monolayer special optical effects cost advantages Textile Special Processes IML
82 Back Molding of textile with In Mold Cutting Introduction Overview Textile Special Processes Future Cutting of edges in the mold Laser technology for flexible cutting and additional operations Back molding with foamed material fully automation of the production machine supplier is more and more responsible for the whole system IML
83 Contents Introduction Overview Textile Special Processes IML 1. Introduction 2. Decoration processes - overview 3. Technology for decoration with films 4. Technology for decoration with textiles 5. Special processes for decoration 5.1 Back Molding with foamed material 5.2 Sequential injection molding 5.3 Compression injection molding 6. In Mold Labeling (IML)
84 Special process: Back molding with foamed material Introduction Overview Textile Special Processes Motivation: Increasing of the free flowing of the plastic material Reduction of wall thickness Reduction of weight (at the same wall thickness) Reduction of warpage Reduction of costs IML
85 Special process : Back molding with foamed material Introduction Cross section of a part molded with structural foam material Overview Textile Special Processes IML Closed cell structure compact surface
86 Special process: Back molding with foamed material Introduction Overview Textile Special Processes Process characteristics for chemical foaming feeding of chemical blowing agent nucleation process for gas bubble production maximum foaming pressure less than10 bar application for bigger wall thickness processing without problems and that which can be retrofitted easily IML
87 Special process: Back molding with foamed material Introduction Overview Textile Special Processes Process characteristics with phys. foaming (MuCell -process) generating of with with direct injection of gas (N 2, CO 2 ) higher foaming pressure and foaming level suitable also for thinner wall thickness additional equipment necessary license fee necessary IML
88 Special process: Back molding with foamed material Introduction Overview Textile Special Processes IML Machine equipment for injection molding of foam : shut off nozzle increased injection speed clamping of injection piston increased platen or Battenfeld 2 platen-imm MuCell -process requires in addition : SCF-System special screw fans for heater bands (similar to PVC-equipment) gasinjector additional software New : Equipment for MuCell -process that which can be retrofitted!
89 Special process: Sequential injection molding Introduction Overview Kavitдt cavity Both nozzles are closed Textile Special Processes IML Melt FlieЯfront one nozzle is open one nozzle is closed both nozzles are opened
90 Special process: Sequential injection molding Introduction Overview Textile Special Processes IML Advantages: shorter flow distance less filling pressure less warpage textile gently no welding lines Disadvantages: more complex mold technology (hot runner with shut off needles)
91 Special process: injection compression molding Introduction Overview Textile Special Processes IML Quelle/Source: Georg Kaufmann
92 Special process: injection compression molding Introduction Overview Textile Special Processes IML Advantages: less filling pressure less warpage textile gently Disadvantage: more complex mold technology (vertical flash face) not for all geometry suitable
93 Contents Introduction Overview Textile Special Processes IML 1. Introduction 2. Decoration processes - overview 3. Technology for decoration with films 4. Technology for decoration with textiles 5. Special processes for decoration 5.1 Back Molding with foamed material 5.2 Sequentiell injection molding 5.3 Compression injection molding 6. In Mold Labeling (IML)
94 In-Mold-Labeling (IML) Introduction Overview Textile Special Processes IML Mainly used for packaging parts (Thin wall) Process : Insert of the label Back Molding Demolding Alternative process: Thermoforming and printing
95 In-Mold-Labeling (IML) Introduction Label () Overview Textile Special Processes IML
96 In-Mold-Labeling (IML) Introduction Container 250 g Overview Textile Special Processes IML
97 In-Mold-Labeling (IML) Introduction Container with film Overview Textile Special Processes IML
98 In-Mold-Labeling (IML) Introduction Overview Textile Special Processes IML Advantages: flexible in changing of decoration, suitable for small numbers advantages in regard of hygienicrequirements very short cycle times up to 16 cavities possible automatic changing of decoration full automatic stacker
99 Thank you for your attention more information :
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