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Technical Moulding: tie-bar-less technology for best-in-class consistency

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ENGEL Fakuma 2015

The significance of multiple component technology in LSR processing is growing. In many applications it is the prerequisite for the integrated injection moulding process that connects thermoplastics and silicone in stable layers. One example of this is diaphragms, as used to ensure functionality and safety in pumps or ventilation systems

In collaboration with its partner Schneegans Freudenberg Silicon (Losenstein, Austria), ENGEL will be producing diaphragms made of glass fibre reinforced polyamide and liquid silicon at Fakuma 2015. The machine used here is an ENGEL victory 200H/60L/140 combi injection moulding machine with an integrated ENGEL viper 40 linear robot. In each cycle, the robot takes off eight finished parts and transfers the PA base bodies to the second set of cavities in the 8+8-cavity serial mould, where they are overmoulded with silicone. While LSR processing is going on, a new set of base bodies is created. In LSR technology, Elmet (Oftering, Austria) is involved in the trade fair exhibit as a further partner.

Automotive: economic processing of premium woods
Premium woods in the automobile interior purvey well-being and a touch of luxury. In collaboration with HIB Trim Part Solutions in Bruchsal, Germany – an NBHX Trim GmbH subsidiary – and other partners, ENGEL has developed a process for economical manufacturing of decor elements with genuine wood veneers. Using the ENGEL clearmelt method, the veneers are back-injected with a thermoplastic in a single step and coated with transparent polyurethane to protect the surface. The method was introduced in 2009, and now the first serial application is imminent. Before the first manufacturing cell designed for production use is commissioned at HIB Trim Part Solutions, it will be producing premium wood decor elements in a 2-cavity mould at Fakuma.
The core of the manufacturing cell is an ENGEL duo 3550/650 combi M injection moulding machine with a rotary platen that supports high-volume production with short cycle times and maximum productivity. On one side of the mould, the wood veneers are back-injected with PC/ABS, while at the same time on the other side, the base elements produced immediately prior to this are flooded with PUR. ENGEL’s system partner for the PUR technology is Hennecke in St. Augustin, Germany. To be able to manage the entire polyurethane process via the display on the injection moulding machine, ENGEL has fully integrated the Hennecke solution into the CC300 machine control unit.
Advances in terms of materials also help to improve the productivity of the ENGEL clearmelt method. The polyurethane used at Fakuma already includes a separating agent, thus saving an entire step. So far, cavity surfaces needed to be sprayed with separating agent before processing PUR.

Teletronics: consistent process integration boosts competitive ability
For the first time at Fakuma 2015, ENGEL is presenting a highly integrated, fully automated process for manufacturing thermal switch housings – from the raw material to the 100% tested and labelled metal/plastic composite parts. The core of the production cell is an ENGEL insert 60V/35 single vertical machine. Upstream of the injection process there are a strip uncoiler, a press module and processing module for tapping a thread; downstream there are quality controls, laser marking and another press module.
Thermal switches, such as those used for monitoring electric motors in automobiles or in the domestic appliance industry, are traditionally produced in a complex, multiple stage process. The metal components are typically punched and overmoulded at different locations. This not only requires a considerable logistics overhead, but also ties up a large amount of material because two independent processes need to be ramped up. This is a considerable cost factor, especially where non-ferrous metals are used.

Fakuma hall A5 – stand A5-5204

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