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Plastics Technology, 2009-02-04, A Quiet Revolution In Materials Characterization
...e never before accomplished, the way plastics materials data are gathered and reported, in order to achieve a quantum leap in the quality, usefulness, and credibility of those data. They agreed on str...

Plastics Technology, 2009-02-04, Novel PC/Polyester Blends Combine Stiffness and Ductility
... by SABIC Innovative Plastics. As we reported initially in November, these PC/PBT and PC/PET alloys achieve this combination of properties through the addition of a third thermoplastic ingredient that...

Kunststoffe international, Award-Winning Packaging Solution ‧Increases Productivity
...d using the IML (In-Mold Labeling) process. A linear handling system per parting line positions the labels precisely and within fractions of a second in the cavity removes the finished parts after the injection process and closes them to achieve a compact packing size. This must be done quickly while the polypropylene is still moldable. After an optical 100 % inspection by a camera system, 38 hinged lids are stacked and banded into packaging units. Nine of these units are packed – also automatic...

Kunststoffe international, Beyond Human Capabilities
...ta into usable information. They will describe the interrelationships for the process setup. Necessary process adaptations for optimal part quality are then passed on to the physical world, e. g. the machine operator. To achieve this goal, the IKV researchers use and implement standardized exchange and storage formats for relevant data. This makes it possible to link a multitude of different components in a uniform format and to derive the complex relationships in the process setup by recording ...

Kunststoffe international, Central Hub for Digitization in Plastics Processing
... 1000 m² technology center, a workshop with an area of around 570 m² for maintenance and service and for building testing molds (Fig. 2). Mold-making is thus integrated directly into the ‧information/value chain to achieve cross-domain collaboration without inform‧ation loss. In the technology center itself, space will be allocated to various testbeds, for example, “complex value chain”, “heterogeneous machinery equipment”, and “material processing”. Here, it is important at the planning and bu...

Kunststoffe international, Correctly Assessing the Energy‧Efficiency of Heating Systems
...lary of this is that more-compact assemblies have an energy advantage. This applies to each of the various components, and ultimately also to the energy balance of the overall unit. The temperature control units supplied by HB-Therm achieve a high level of energy efficiency because they are well insulated, their smaller surfaces have better ventilation designs and the number of ventilation slots has been kept to a minimum. “Users have confirmed this efficiency to us,” says Rottach. Insulation an...

Kunststoffe international, Delivering Efficiency Even in Harsh Environments
...ds. However, miniaturization resulting in smaller nodes down to 5 nm potentially makes chips more prone to damage during processing. Longer operating time, less downtime and an up to 3 % productivity increase can all be achieved for example by using CMP rings made from Victrex PEEK (Fig. 2). The material is around two times more wear-resistant compared to polyphenylene sulfide (PPS), i. e. they have been proven to run up to two times longer than PPS before replacement is necessary. In addition,...

Kunststoffe international, Drivers of Electromobility
...ster (TCP) grades. Among all these polymers, PA6, PA66, PA 4T, PBT and PPS are very well suited to the needs of the electric powertrain. Quite often, halides such as copper-iodide (CuI) based heat stabilizers are used polymers to achieve good thermal resistance. This keeps the mechanical properties of the structural or insulating plastic on a high level even at long term exposure to elevated temperatures. Heat and humidity, however, can cause some hydrolysis in the plastic, during which iodide (...

Kunststoffe international, Easier to Reach the Destination
...en contained up to 20 % or more filler, yet today’s materials may contain 10 % or less. To use the example of door cladding materials, which nowadays can boast densities lower than 1 g/cm3. One material solution used to achieve this is Daplen EE001AI, a highly impact-re‧sistant PP compound providing very good surface aesthetics and scratch resistance – and a density of only 0.95 g/cm3. Above and beyond its pleasing aesthetics, Daplen EE001A1 also fulfils other demands placed on interior materia...

Kunststoffe international, Everything Keeps Flowing
... extends the flow path of the melt with the same process parameters. In addition, depending on the processing viscosity, there is an optimum structural density for the longest possible flow paths. Injection molders can use this knowledge to achieve longer flow paths with the same machine technology. If the structure is applied to the moving side of the mold, no impairment of visible surfaces is to be expected. It remains to be checked how a structuring applied on both sides affects the flow path...

Kunststoffe international, Exhibitors See Green
...customer interest in sustainable, carbon-neutral and resource-efficient modes of production, and offering products and services intended to satisfy this interest. In addition, the greatest innovation driver for many companies is still the urge to achieve complete networking of all the steps involved in production. Irrespective of whether it concerns manufacturers’ proprietary system environments or supplier-independent networking: communication internally between equipment and systems and with p...

Kunststoffe international, Fine Adjustment of the Melt Flows in the Hot Runner by Means of Melt Rotation
...hannels of manifold systems can result in the various mold cavities producing molded parts with different properties – in spite of natural balancing and optimum mold quality. This situation can be remedied with a fine adjustment of the melt flows, achieved using melt rotation. If you look at the key data for our example – the inner shell of a double-walled thermal mug made of PC (Fig. 1) – everything seems to have been done correctly:A mug-shaped, rotationally symmetrical molded part,central gat...

Kunststoffe international, Glass Fiber-Reinforced Polyphenylene Sulfide Made Weldable
...stic polymers, unfilled, are transmissive enough for the wavelength range of the commonly used laser sources (typically 808–1064 nm) to be used as laser transparent joining partners. In contrast, the desired absorption behavior is usually achieved by using additives, in the simplest case by particle soot. A typical overlap configuration of laser transparent (natural) and laser absorbing joining partner (black) is shown in Figure 2 using laser-welded PPS sample plates from DIC Corporation. Howev...

Kunststoffe international, Green Shape Changers
...g demand for efficiency and resource conservation, shape-changing (smart) materials offer a sensible approach to integrating functionalities into a component without giving rise to additional energy and material costs. Even greater sustainability is achieved if the components are produced from bioplastics. Numerous developments are inspired by nature. Few technical components are so well adapted to their specific requirements and so well equipped with additional functionalities as naturally occu...

Kunststoffe international, Influences on Microdamage Strain Limits
...ty improved. However, it would be unrealistic to expect to achieve much more accurate or apposite results. This is because the mathematical model, which is formed from the deformation condition (1) and the various influencing factors, is but an imperfect representation of complex reality – as is true of all mathematical models. And again, the more detailed the analysis, the more open questions that are raised. Nevertheless, or precisely because of this, the results presented here can be helpful ...

Kunststoffe international, Killing Problem Microbes
...fungi, algae, and yeasts. Application kinetics have been worked out and can be customized for online spray, dip, or kiss roll treatment application post extrusion or thermoforming plastics. Followed by thermal or UV curing, plastic manufacturers can achieve bacteriostatic [1], fungistatic [2] and algaestatic [3, 4] control, inhibition and protection. This article describes how these novel chemistries work on plastic surfaces, their regulatory status and details how producers of plastic goods can...

Kunststoffe international, No Chance for Dust and Contaminations
... both in term of part shapes and process parameters are discussed and representative sample are presented. Surface Modification to Allow New LSR Applications For standard LSR parts, it is know that such a surface modification can be achieved by high-energetic UV-photons. However, for optical LSR parts the influence of the treatment on optical and geometrical characteristics is unknown. What is the effect of the UV exposure? To achieve the effect, the surface is irradiated with 200 nm max. typic...

Kunststoffe international, No More Weight Problems
...process technology developed by Wittmann Battenfeld GmbH, Kottingbrunn, Austria. The software “HiQ Flow” takes care of monitoring, recording and controlling viscosity deviations during the injection and holding pressure sequence in order to achieve a consistently high parts quality regardless of the material’s viscosity. How Does the Assistance System ‧Function? Low-viscosity materials require less pressure to fill the cavity than melts with a higher viscosity (and vice versa). If the viscosity...

Kunststoffe international, Nozzles Regulate Thickness
...on, spiral mandrel dies are typically used in which the name-giving overlapping spirals produce a largely uniform distribution of the melt over the circumference. However, a completely homogeneous volume flow distribution at the die outlet cannot be achieved in this way, especially if the volume flows entering the spiral mandrels already differ from each other. The reasons for such deviations are local temperature differences in the die material and the different shear forces experienced by the ...

Kunststoffe international, Polymer Materials
...1868/70), they were used, among other purposes, to imitate and substitute for ivory, horn, tortoiseshell, coral, and mother-of-pearl. But, of course, not just for that, since from very early on unique patterns and colors were achieved with Celluloid that had no models in nature. Nevertheless, students of art history are still taught that the early plastics just fulfilled a substitute role and carried the taint of being artificial, inferior, cheap, and mass-produced. In Germany, this image was pr...

Kunststoffe international, Polypropylene Beats Aluminum
...impact-resistant battery tray system. It had to weigh no more than an aluminum component and incur no significant extra costs through the use of expensive materials such as aramid fibers or titanium. In the interest of sustainability, the aim was to achieve the greatest possible recyclability of the materials used and the finished battery tray. The battery trays in electric vehicles are primarily underbody systems designed to protect the batteries from impact stresses arising from the road. Thes...

Kunststoffe international, Present in a Multitude of Trends
...e wide scope for coating and surface design. Glass-like effect coatings, for instance, can be used to enhance the carbon look that comes from the fibers. Graining and even textile effects can also be achieved. In addition, the surfaces can be coated with scratch-resistant polyurethane hardcoats (PU) or self-healing PU coatings using in-mold coating. The range of applications for CFRTP with PC matrix extends from automotive and mechanical engineering to the electrical, electronics and consumer go...

Kunststoffe international, Printed Tools for High-Volume Production
...osites for use with Ultimaker 3D printers. In the Ford example, both Ford’s original material profiles and those of Ultimaker were used; in addition, the developers had to create many Ford profiles themselves or request them in order to achieve the desired result.Further Conceivable Fields of Application The advantages of desktop 3D printing are many. They include comparatively-low production costs considering small batches, faster availability in the event of an unplanned need, and weigh about...

Kunststoffe international, Putting Hybrid Components to the Test
...lyphenylene sulfide (PPS), which is particularly well suited for many such e-mobility applications inside the vehicle. A challenge, however, is that the busbars and other electrical components need to become more compact and lighter (Fig. 1). To achieve this, the metal conductors must be situated closer together, increasing insulation requirements. At the same time, the power and voltage requirements of the vehicle are increasing, leading to greater temperature swings in the component. These fac...

Kunststoffe international, Reactive Extrusion of TPU
...er shear. The possibility to completely avoid the use of solvents is a notable environmental advantage. REX is particularly suitable for the production of TPU systems, but it requires a high degree of process control to consistently achieve the desired product quality. This is due to the complex relationship between the progress of the reaction and the properties of a flowing melt with a constantly changing viscosity. Under these ‧circumstances, finding the processing window suited to the prope...

Kunststoffe international, Real-Time Process Monitoring in Cleanroom Environments
...usky Company, in the design of electric actuators ensures that the ideal actuator is selected for every injection mold and every application. In addition to the maximum force, the acceleration of the movement is also taken into account in order to achieve the shortest possible cycle times. The applications are varied and include not only unscrewing and ejection movements but also combined movements, which are realized for example in compression molds and electric valve gate systems. For example,...

Kunststoffe international, Replacing Metal in the Gearbox
...on fiber content. The fork is now ready for mass production, is 35 % lighter than its metal counterpart, meets all specifications and has already passed endurance tests on test rigs. The German Dresden-based development team could not have achieved this success without possessing sound technical knowledge and a certain amount of technical flair, as there were many issues to be addressed, studied in simulations, and resolved with great precision. Trojan Work at up to 160 °C What is a shifter fork...

Kunststoffe international, Reverse Rotation
...ew system’s technology, real-time monitoring of the manufacturing process and intensive tool monitoring were set up. Automated Monitoring and Control of the Manufacturing Process To achieve the required reliability and quality of finished work, two independent monitoring systems were installed as part of the Reverse Cube system. One regulates and monitors the quality of the parts. The other controls the condition of the injection molds and cavities. “We ensure consistent part quality using the a...

Kunststoffe international, Starting up under the Shadow of Corona
...ompanies. It’s undeniable that it would sometimes be desirable to be faster in addressing this or that issue. But here, too, there is global competition, which allows innovative companies to achieve higher margins, though they are permanently on trial, and by far no longer in such a comfortable position as they used to be. The big sellers today are digital products, which our industry doesn’t manufacture. Prof. Hopmann: Autonomous driving is a good example, since there are many patents about thi...

Kunststoffe international, Sustainable Growth
...tyrene turned out to be higher than 99.9 %. Tomra’s findings prove that today’s sorting technologies achieve a purity level beyond what is required to successfully recycle polystyrene through both mechanical as well as advanced recycling processes. A first life cycle assessment analysis has also been completed for depolymerized styrene according to the ISO 14040 and ISO 14044 standards. Results were presented for the first time by Ineos Styrolution. A laboratory scale project shows greenhouse g...

Kunststoffe international, Symbiosis of Toolmaking and Serial Production
...nce measures. For this reason, close and cooperative partnership between serial producers and toolmaking companies is essential for the application of predictive maintenance. This allows productivity gains and mutual competitive advantages to be achieved through knowledge sharing. Structure and Objective of the Guideline The development of predictive maintenance systems is particularly interesting for injection molding companies and their mold-making partners who repeatedly experience tool-rela...

Kunststoffe international, The One that Shears, Splits, and Folds Material
...uction quantities and growing demands for reproducibility, those systems became interesting that could compound continuously (see Box). From the Idea to a Wide Range of Applications The success that a screw machine can achieve for a single application depends on how well its strength profile corresponds to the specific requirements [5]. As systematic investigations have meanwhile shown [6], this suitability can be evaluated in advance by modern analytic methods, if the strength profile of the...

Kunststoffe international, The Switchover Problem and its Consequences
...s leads to insufficient quality of the injection mold‧ed parts [1]. The ideal switchover time is when the melt front reaches the end of the flow path. The pressure curve in the transition between the two process phases should also be constant to achieve high part quality [2]. A premature switchover causes a pressure drop in the cavity, which may result in switchover marks or sink marks on the part surface. If the switchover process is executed too late, pressure peaks occur which can lead to hig...

Kunststoffe international, Turning Old into New
...d of 400 rpm to 61.1 g/10 min at 1200 rpm. As a result of the increased surface renewal at increasing screw speed, the polystyrene is degraded more strongly and a higher MFR value is achieved. Titanium dioxide as a filler does not lead to a clear effect. At a low screw speed (400 rpm) a high MFR value of 75 g/10 min is achieved. In contrast to carbon black, a high screw speed leads to a reduced MFR value of 61.85 g/10 min. These trends are also confirmed by observing the glass transition temper...

Kunststoffe international, What Can You Do at Fall Fairtime, When There Aren’t Any?
...of its main emphases, KraussMaffei chose Silco‧Set technology (Fig. 5) which paves the way for users to achieve zero defect production in silicone processing. Precise temperature control as well as highly precise injection (thanks to minimal holding pressure) and locking behavior are the preconditions for the reliable processing such low-viscosity materials as liquid silicone (LSR). Premature networking is precluded by constant cooling, thus assuring stable thermal conditions for plasticizing. P...

Kunststoffe international, 2005-11-21, "Alliances increase Competence"
...irector of marketing of the company's European plastics division. The Raw Material Producer as "Solution Provider" According to Heider, in the face of reductions in the price of technical thermoplastics a plastics manufacturer can only achieve growth and profit if it is a technology leader and a "solution provider" for the customer. Therefore, besides high quality products, Bayer also provides a complete service package. This extends from research and development to advice ...

Kunststoffe international, 2005-11-21, 3D Simulation: Simulation of Foaming Polyurethanes
...he occurrence of entrained air and defects may appear in the approach, but a prediction as to where these will be “convected” is hardly possible (Fig.2). In the simulation tool that has been developed, a sufficiently sharply defined surface is achieved through use of a variant of the VOF model [8], and the ambient air is taken into consideration as a compressible gas phase (Fig.3). In this way, it is possible not only to recognise the presence of entrained air, but also to see where the inclusi...

Kunststoffe international, 2005-11-21, A Commonsense Quota System
...alyses of the freedoms of manoeuvre in terms of technical design demonstrate that the potential for improving environmental soundness by means of lightweight engineering is immeasurably greater than that which, in the best-case scenario, can be achieved by the difference between material and energy recovery of ELV plastics (Fig.3). When on the horns of a dilemma which permits only one decision, either in favour of lightweight engineering or in favour of recyclability, the decision in favour of l...

Kunststoffe international, 2005-11-21, A Comparison of Drive Technologies
... machine manufacturers and processors [1–5]. Selection Criteria for Machines and Companies The aim of this survey is to make an objective comparison between all-hydraulic and alternative injection moulding machine drives in practical use. To achieve this aim, a basic prerequisite was established for comparison of the measurement results: a comparison can only be made if the machines come from one and the same machine manufacturer and are used to produce the same product. Another boundary...

Kunststoffe international, 2005-11-21, A Comparison of Temperature Control Systems: Optimum Thermal Design of Injection Moulds
...an important prerequisite for economic manufacture of high-quality injection moulded parts. The engineers responsible for part and mould design need to strike a compromise between the level of the mould costs and the cycle time reduction that can be achieved. A major German supplier to the infocom indus-try has conducted research into current technology. Carsten Brockmann Simon Rupp In a fully automatic injection moulding production line for shell-type articles in the mobile communications indu...

Kunststoffe international, 2005-11-21, A Contradiction in Terms?
...for "design for recycling". With the adoption of the EU End of Life Vehicle Directive, the subject of recycling has again moved into the foreground. In addition to the possibility of cost-free take-back for the last owner, the quotas to be achieved are of vital importance: - from 2006: > 80 % material recycling (including reuse) and > 85 % total recycling (reuse, material recycling, thermal energy recovery) and - from 2015: > 85 % material recycling (including reuse) and > 95 % total r...

Kunststoffe international, 2005-11-21, A Demanding Body Care Set
...en the cover (Fig.3). The housing interior and the undercut for the bore of the pressure setting switch of the Visapure luxury model are formed by a core puller with a mounted crank-operated drag slide (Fig.4). The opening for the drive shaft is achieved by demoulding a core at the ejector side, which is moved by means of a core-puller slide, and an upwardly angled, externally running core-puller slide, combined with a further flush-mounted slide. The core for the brush drive is released by mean...

Kunststoffe international, 2005-11-21, A Systematic Approach to Micro-Injection Moulding
...es that may be necessary. It is also essential to establish whether a variotherm temperature control will be required when the moulding compound is injected into the cavity so as to ensure that the microstructure is correctly reproduced. This can be achieved through an inductive heat-up, followed by shock cooling with water or CO2. The actual definition of micro-injection moulding applications is a very wide one, which deliberately leaves room for interpretation, and should also not be restricte...

Kunststoffe international, 2005-11-21, Acceleration is Not Everything
...such as the new, single-axis, high-speed ERS demoulding device from Engel (Fig. 1), surpass the natural force of gravity many times over. With an acceleration of over 110 m/s2 - more than 11 times the force of gravity - speeds of a good 8 m/s can be achieved. Such extreme acceleration is achieved both with the aid of a highly dynamic servomotor having particularly low dead weight-inertia moments and through the use of particularly high-strength, lightweight materials, such as aluminium and carbo...

Kunststoffe international, 2005-11-21, Additives
...ariocrom series (manufacturer: BASF, Ludwigshafen/Germany) provide a special effect. The colour shade undergoes a change – such as from green to red (grade: Magic Green K 9811) – depending on the angle from which it is observed. This is achieved through the interplay of light interference and refraction on iron oxide and silicon dioxide layers that are applied to micaceous iron oxide plaques (MIOX), as shown in Fig. 6. Conventional Cu phthalocyanine blue pigments have a negative influence on the...

Kunststoffe international, 2005-11-21, Additives: Custom-engineered Plastics
...omated flame retardants have been blacklisted within the European Union, the demand for halogen-free systems has grown. For production of PE and PP cable insulation, aluminium and magnesium hydroxides represent suitable replacements. In order to achieve adequate protection, however, the hydroxides must be used in large amounts, which has a negative impact on the mechanical and electrical properties. Süd-Chemie offers a solution with a new nanofiller. Thanks to the small particle size and good we...

Kunststoffe international, 2005-11-21, Additives: Tough and Heat-resistant: New Silicone Particles for Thermosets
...exible core is produced from organic rubbers, e.g. acrylate- or butadiene-based. The above-mentioned disadvantages of the reactive, organic liquid rubbers are therefore only partially overcome; similarly, the organic rubber grades do not achieve the high-temperature resistance often required [1]. With soft, flexible cores based on silicone rubber, however, it is possible to overcome these disadvantages. For example, resistance to thermooxidative degradation is very high and water absorption low...

Kunststoffe international, 2005-11-21, Air Ducts under the Bonnet
...ies. Grilon ELX exhibits superior damping to TEEE in the relevant temperature range for under-bonnet applications. For air ducts in the engine compartment, decoupling from vibrations is important. With Grilon ELX, a high degree of decoupling can be achieved. The good vibration-damping properties of Grilon ELX also provide better sound-deadening. Another property in which Grilon ELX comes out significantly better than TEEE is heat ageing. For example, both Grilon ELX grades retain 90 % of their t...

Kunststoffe international, 2005-11-21, Airbag Module in PA 6 Recyclate
...omponents. This is a heat-stabilised, impact-modified PA 6 injection moulding grade, reinforced with 40 % glass fibre, for moulded parts offering increased toughness in the freshly moulded state and with improved strength and toughness overall. It achieves the performance characteristics of a high-impact glass fibre reinforced polyamide with shorter cycle times and an optimised surface quality. At the start of the recycling process, scrapped airbag housings in plastic and also post-consumer wast...

Kunststoffe international, 2005-11-21, An Overview: Innovative Processing Techniques
...o survive at an international level, auto makers and their highly specialized suppliers not only have to continually come up with new ideas for products, but they also have to extract the maximum amount of economic benefit from them. In an effort to achieve improvements that go beyond the state of the art, novel ways of processing engineering plastics are being explored. Innovative processes can provide benefits in the form of lower weight, fewer parts for saving on assembly costs, shorter cycle...

Kunststoffe international, 2005-11-21, Attractive New World of Packaging
...ling plants. For them, the initial investments are comparatively low compared with those of manufacturers of glass and metal packaging. This intensifies competition. “This is why every single increase in efficiency we can achieve is vital to enable our customers to gain a reasonable return”, says Cook. One-stage Production of Preforms and Bottles Husky is now introducing another important development onto the market under the name “Index SB”. It is a one-stage machine for the integrated inject...

Kunststoffe international, 2005-11-21, Automation Around Injection Moulding Machines
...f old has developed into a specialist with knowledge of process automation, robotics, sensor technology and various different technical disciplines. Even where these high-end applications are not needed, high efficiency for the entire process can be achieved by specific application of for example part removal methods designed for the particular situation together with automated material supply. Fig. 1 shows an example of a defined supply and/or intermediate temporary storage of injection moulded...

Kunststoffe international, 2005-11-21, Automation: Maximum Networking of Manufacturing Processes
...ion To maintain high part quality, automation of insertion processes, for example, is becoming more important. Many of the integrated project solutions now concern the automatic insertion of components or parts. The constant cycle that can be achieved not only provides the necessary product quality, it also improves efficiency by increasing yield. Additional unmanned shifts are also easy to realise in this way, since testing for quality assurance can be readily integrated into the overall seque...

Kunststoffe international, 2005-11-21, Automobile Construction: A Substitute for Sheet Metal
...PA 6-semi-finshed materials were their outstanding ten-sile strength (114N/mm2) and excellent stiffness (Young’s modulus: 5800N/mm2)“, Norbert Hendel, technical marketing expert at Sustaplast, outlines. Such stiffness makes it easier to achieve low wall thickness values, in comparison with other mate-rials. Although the engine covers have large dimensions, they are characterised by low distortion and dimensional stability. They are also very break-resistant, since the PA 6 has been modified to ...

Kunststoffe international, 2005-11-21, Automotive Applications: Thermosets Get Going
...ts on account of flow lines, a lateral gate was selected which was supported by semi-compression from the side remote from the gate. This permitted flow lines to be more or less avoided in their entirety and a homogeneous fibre orientation to be achieved, which meant that the parts passed the temperature cycling tests involving more than 1000 two-hour cycles between -40 and +140°C as well as the limiting creep stress test with more than 3x107 cycles. By employing a moulding compound with low-den...

Kunststoffe international, 2005-11-21, Automotive Glazing: Clear Prospects
...d GE Advanced Materials. These produce durable, weight-saving and high-performance glazing systems for the automotive industry. If the characteristic integration potential of the engineering thermoplastic is exploited to the full, it is possible to achieve weight savings of up to 50% on large-area sun roofs and tailgate windows in polycarbonate compared with comparable systems in glass. At the same time, the time and effort involved in assembly can be cut back considerably. GE Advanced Material...

Kunststoffe international, 2005-11-21, Automotive Industry Revives Business: Thermosets
...so that they can flow efficiently through the hose lines into the reinforcing material. Curing exothermy should only lead to temperatures up to 45°C, which can be adjusted via resin reactivity. Low-styrene resins have lower shrinkage but to achieve easy flow, DCPD resins are often employed in the marine industry. Newly developed orthophthalic acid resins with reduced styrene content meet the market demand for unsaturated polyesters that can satisfy higher standards in terms of water resistance a...

Kunststoffe international, 2005-11-21, Bank Rating: Corporate Financing in the Shadow of Basel II
..., the Capital Accord that is planned to come into force in 2007 (cf. the second consultative paper of the “Basel Committee on Banking Supervision”), the capital requirement will be oriented to the creditworthiness of the borrower. Its aim is to achieve just consideration of credit risks, in other words a poor credit standing will lead to poorer credit conditions and vice versa. There is, in fact, already a tendency for credit institutions to adopt a more restrictive lending policy, varying accor...

Kunststoffe international, 2005-11-21, Bank Rating: Leadership – An Important Rating Factor
... partly responsible for the rating result. The question now arises: "Is there a style of leadership that positively affects the rating?" Manner of Leadership Leadership essentially involves exerting a specific effect on others in order to achieve corporate goals. Leadership behaviour covers all a manager's perceptible methods of behaviour and skills connected with fulfilling managerial duties. The style of leadership is expressed by the manner in which the workforce is managed. Huma...

Kunststoffe international, 2005-11-21, BASF and its Customers: Profitable Growth
...Oil & Gas divisions as well as for coordinating the implementation of this corporate guideline. "We have set ourselves the goal of specifically cooperating with innovation leaders. Through joint development work with customers, we are seeking to achieve added value together. BASF will create a global campus for analysing markets and collaborating with customers to boost innovations. Examples of existing close, profitable partnerships are those with the sports equipment manufacturer adidas-Sa...

Kunststoffe international, 2005-11-21, Biodegradable Film: For the Sake of the Environment
...and feedstuffs. Biodegradable materials are materials that can be broken down by microorganisms or higher organisms. Through the use of biodegradable materials from renewable raw materials, it is possible – in contrast to synthetic plastics – to achieve a natural material cycle. There are, however, other advantages as well: - Renewable raw materials are largely CO2-neutral. Their use does not cause any additional greenhouse effect. - Natural resources like crude oil, which are not available in...

Kunststoffe international, 2005-11-21, Blow Moulding: More than Hot Air
...of PP, and Aoki are sticking by this raw material, whereas Krones, despite the cost advantages of PP, is showing a bit more reluctance because of PP’s poor barrier to oxygen. Faster, Smaller, Cheaper The race that was already apparent at K2001 to achieve ever higher output in the stretch-blow moulding of PET bottles is still in full swing. Even as a spokesman for Sidel said that his company was no longer quite so committed to this race, other machine manufacturers were serving up new records. I...

Kunststoffe international, 2005-11-21, Blown Film Extrusion Today
...roducts and diminishing batch sizes. This imposes demands on plant technology, since in addition to high product quality and output rates, flexible production with a wide range of materials and minimum downtime for colour or material changes must be achieved. Purging operations lasting several hours with the associated material wastage are no longer acceptable. Against this background, the status of blown film technology is reviewed in this article by discussion of the main plant components. Dr...

Kunststoffe international, 2005-11-21, Bond Reliably: The Right Adhesive
...ght Adhesive Bond Reliably. The property profile of polymeric materials also affects the bonding or joining method employed. Classical methods such as welding are often not suitable, so that bonding technology is gaining in importance. In order to achieve a successful bonding, however, certain basic prerequisites must be met. Gudrun Weigel With about 15 wt.-% in new car models, plastics represent the second largest materials group in the automotive sector and show a wide range of properties:...

Kunststoffe international, 2005-11-21, Bonding of Plastics
... low heat input or none at all. The structure of the adherends remains virtually unchanged and deformations or internal stresses due to heat incorporation are a rare occurrence. Even plastic-metal bonds are possible, a feat that not even welding can achieve. Bonding as Economic Factor Bonding technology has now become an economic factor that should not be underestimated, neither by users nor by adhesive manufacturers. Adhesives permit a level of wealth to be created that was not possible befor...

Kunststoffe international, 2005-11-21, Boost for the Economy: Becoming More Competitive through Co-operation
...astics industry. It was intended to strengthen the innovativeness of plastics companies, especially through co-operative networking. Methods developed in the PC make it easier to create a basis for successful co-operation. Based on the pioneering achievements of three companies – Gebrüder Anger, Kremstal, in the field of machine and mould construction, Engel, Schwertberg, in the field of injection moulding machines, and the former Austrian Stickstoffwerke (later called Chemie Linz) – the plasti...

Kunststoffe international, 2005-11-21, Broad Range of Application: High-density Polyethylene (PE-HD)
...gy, Product Development Bimodal PE-HD grades have become established on the market in the meantime, especially for applications such as film, pipes and hollow articles. The low wall thicknesses and more favourable processing behaviour that can be achieved with these products have economic advantages for converters. New PE-HD facilities are currently already being designed for the production of trimodal products (Basell). A new generation of PE-HD is evolving here which, although it will not fun...

Kunststoffe international, 2005-11-21, Calcium Silicate as a Functional Filler: Wollastonite – a High-performance Filler
...epared needle-like particles. Thanks to these crystallographic properties, the filler can also offer the required high tensile strength. With a coated wollastonite powder, good adhesion to the filler-polymer matrix interface is additionally achieved by chemical or physical bonding. In injection moulding, the needle-like wollastonite particles are oriented in the lengthwise direction. As a result, shrinkage in the direction of the needles is prevented. The low thermal expansion coefficient (7
...

Kunststoffe international, 2005-11-21, Cards are Trumps – Chip Card Bodies for the World Market
... EUR 2.1 million and an EBIT of just under EUR 200,000. For the current fiscal year, Proske is looking to sell some 100 million cards with sales of EUR 2.8 million. “If we carry on developing this way, we will actually achieve our target of EUR 5 million in our fifth financial year.” CSC’s business strategy of concentrating entirely on the production of the card bodies and selling them to the chip card manufacturers evidently convinces the people in the industry. At the beginning of the year, fo...

Kunststoffe international, 2005-11-21, Case Study (3): Hot-Runner Solution for a Spring Valve
Hot-Runner Solution for a Spring Valve Case Study (3). Automated injection moulding production is often difficult to implement for small parts, since the demand for direct gating of the parts is rarely possible to achieve. Nevertheless, with standards and mini hot-runner systems developed especially for this type of application, and the smallest possible moulds on small injection moulding machines, cost efficient solutions are possible, as this case study shows. Dirk Paulmann In the injection ...

Kunststoffe international, 2005-11-21, Case Study (4): Hot-Runner Solution for a Spectacle Case
... mould inserts were used to compare different mould surfaces, materials and coating processes. The chosen hot-runner system must be able to process a wide range of different plastics reliably and without stressing the material, and be able to achieve two different gating positions with the same hot-runner manifold. Requirements on the Hot-Runner System In contrast to normal production moulds, flexibility and versatility were paramount in the choice of the hot-runner system. The range of materia...

Kunststoffe international, 2005-11-21, Case Study (5): Hot-Runner Solution for a Four-Gang Switch Plate
... a bush with a conical melt bore that enlarges from 5mm to 12mm is used. The hot-runner nozzles Z33201, with screw-fitted gate bushes, that are used are characterised by their homogeneous temperature profile. It is particularly important to achieve a smooth melt-flow transition from the manifold riser bores to the melt bores of the nozzles. The transitions were made conical and the manifold movement occurring as a result of thermal expansion was computed and compensated for in the dimensions (Fi...

Kunststoffe international, 2005-11-21, Case Study: Hot-Runner Solution for an Electronics Coil
...alled product and the high viscosity of the polymer to be processed, the process builds up high injection pressures, which the hot-runner system used has to be able to resist permanently and reliably without leaking. It is just as important to achieve a minimum stress during cavity filling by suitable choice of gate position and low pressure losses in the hot-runner system. The polymers used for part production contain large proportions of glass fibres and flame retardants. Both abrasive wear a...

Kunststoffe international, 2005-11-21, Centralized Supply for 59 Injection Moulding Machines
... with automatic Super-Somos device installed in the dry-air dryer and controlling the most favourable regeneration frequency fully automatically as a function of material throughput and moisture content. The reduction in energy consumption that this achieves brings considerable cost savings. - External heater. - Four Somos drying hoppers: one with 600 l, one with 800 l, and two with 1200 l volume. - Automatic load adaptation valves (ALAV), which adapt the dry-air flow rate to the respective pell...

Kunststoffe international, 2005-11-21, Ceramic Injection Moulding in Practice
...he green part to a magazine (Fig.2). Thus for the following production steps it is not necessary that the ferrule be handled individually. All the components of the quadruple injection mould in contact with ceramic are made of tungsten carbide to achieve as long a lifetime as possible. A special mechanism in the mould comprises mobile cavities, whose opening during injection is controlled by a hydraulic counter-pressure. This prevents free-flow formation and ensures even filling. In the cavities...

Kunststoffe international, 2005-11-21, Choosing Plugs: Plugs for Forming Cups
... in the wall area of the cup and to attain a thinner base of the cup. - Plug B: Like plug A, but with no softening in the wall region. - Plug C: Plug face with a hutch and lateral undercut, both intended to avoid local film cooling. The goal is to achieve uniformity of the cup wall and a thin cup base. - Plug D: Lateral undercut and lobe on the face to avoid local film cooling and to promote slippage over the rounded plug edge. Goals: Uniformity and a thin cup base. - Plug E: Lateral undercut f...

Kunststoffe international, 2005-11-21, Cleanroom: Cleanliness is the First Commandment
... or against one of the procedures depends predominantly on design and functionality considerations. A crucial criterion for acceptance by the manufacturer is as high quality a surface of the PMMA displays as possible without scratches. In order to achieve this quality Balda makes large investments according to Ralf Ackermann from the executive committee for production. The hall where the machines for PMMA processing are located is air-conditioned and a slight positive pressure is maintained in o...

Kunststoffe international, 2005-11-21, Coating Carpets
...ts composite carpets to be produced in a single operation. The only brief, unilateral thermal stressing that prevails preserves the pile fibre and ensures good dimensional stability over the entire carpet structure. Final widths of 4 and 5 m can be achieved on an extrusion coating plant thanks to the variable coating widths. Production speeds of up to 35 m/min are possible. The extrusion coating process can be either installed as an all-in plant or incorporated in existing latex foam coating uni...

Kunststoffe international, 2005-11-21, Coinjection of Thermoplastics and Elastomers
...rowing demands of the function and design of the parts, and continuing developments in thermoplastics elastomers. In many applications, however, the resistance to chemical environments and high temperatures must meet even higher demands [1]. This is achieved by curable elastomers, i. e. organic rubber and liquid silicone rubber (LSR). In the coinjection of thermoplastics and crosslinking moulding compounds, the considerable differences in processing conditions must be taken into account, which p...

Kunststoffe international, 2005-11-21, Coloured PPVC Films: Colour Makes the Difference
... with deionised water. Although the UV radiation in the solarium was slightly less than the output of Xentotest instruments or Weatherometers, the black standard temperature was about 20 to 30°C higher (about 90°C), so making it possible to achieve significantly accelerated sample aging as compared with standardised weathering units. For each shade, four small samples (5cm x 6cm) and five DIN A4 sheets were placed in the solarium. In the case of the small samples, weight loss was determined and...

Kunststoffe international, 2005-11-21, Combined Process: Foamed Parts with Excellent Surface Quality
...ages of both processes. The example in Fig.5 shows how the advantages of the MuCell process are retained. The bottom shell of the chair, with a foamed core (ABS, red) and an unfoamed skin (ABS, black), by comparison with unfoamed parts, achieves: - a weight reduction of 13%, - a cycle reduction of 24%, and - a reduction in clamping force from 2750kN to 700kN. By this means it is also possible to achieve a reduction in part costs of about 20%. Fig.6 makes clear, with the example of an automotive...

Kunststoffe international, 2005-11-21, Comparative Study: Virtually Equal in Terms of Precision
...gh injection ve-locities of up to 400 mm/s. In the injection phase, the energy stored in the hydraulic accumulator ensures high acceleration; active retardation of the screw advance velocity is provided by the position control of the screw. To achieve optimum melt quality, the studies were carried out with screws with L/D 20 and new quality process units. The machines under considera-tion recognise the changeover point in the control in less than 100 µs. A Comparison of Sensors In an analysis ...

Kunststoffe international, 2005-11-21, Complete Automation: Articulated-arm Robots for Difficult Assembly Operations
...ality improvement compared with manual production? Riegger: We have realised genuine full automation on our plants, i.e. all steps in the process chain are automated — from parts removal through to final packaging of the parts. We achieve maximum efficiency by achieving faster plant availability when we change the version of the moulded parts. A direct qualitative relationship results from the greatly reduced number of start-up parts. Plast Europe: Why did you opt for a six-axis robot? Riegger:...

Kunststoffe international, 2005-11-21, Component Design: Creep Resistance - A Characteristic Value for Creep Behaviour
...antified and put on a more objective footing with the aid of the characteristic value of creep resistance. A new characteristic value naturally only makes sense if it is generally accepted. This article, therefore, sets out to achieve this objective by presenting the characteristic value of creep resistance for discussion to interested parties in the specialist worlds of teaching and application technology. The author thus looks forward to a keen exchange of opinion and would like to thank his ...

Kunststoffe international, 2005-11-21, Composite Parts: Flexibility in Rigid/Flexible Combinations
...blem encountered with rigid/flexible combinations is the selection of appropriate materials for the substrate component. Different types of connection are possible as a function of the material combination employed. The simplest connection is one achieved through adhesion. If the two components cannot be reliably joined in this way, then the designer must provide assistance in the form of undercuts or perforations. The contour of the interface layer additionally has an influence on the adhesion,...

Kunststoffe international, 2005-11-21, Compounding: Flexibility for Compounders
...e production time. Every compounder can work out for himself how quickly investments will pay for themselves. Not only does the extruder alone have to be taken into account, but also the whole compounding plant. A refitting time of 15 minutes can be achieved only by overarching planning, including the metering and regulating system. Leistritz therefore takes on the task of full integration and offers the compounder a turnkey system (Fig. 5). More Flexible Use of Compounding Equipment Most comp...

Kunststoffe international, 2005-11-21, Compounding: Maximising Use of Machine Potential
...ssing parameters. Details of these models can be found in [1–3]. The models for calculating the dissipated energy are based on numerically determined values, which can then with the aid of statistical methods be described by powerful equations. To achieve the optimum descriptive quality, higher-order polynomials are used here: > To evaluate the accuracy of the model, simulation calculations were carried out using a finite element program [4]. To obtain meaningful results that were as generally...

Kunststoffe international, 2005-11-21, Compounding: Throughput-determining
...s development aim is also shared by Leistritz Extrusionstechnik GmbH, which kept its new Double-X model compounds top secret in advance of the trade show. The new ZSE-Maxx models will gradually supersede the former HP series in future. The series achieves an input increase of 25 to 35% thanks to an optimised volume-torque ration with a Do/Di ratio of 1.66. The centrepiece of this invention is the patent-pending maXXshaft shaft-hub joint, which not only offers higher torque, but also an increased...

Kunststoffe international, 2005-11-21, Compounds and Blends Made to Measure
...the price can be reduced by appropriate selection of compounding materials and foaming agents. One of the foci of the work done today by the Luvocom team at Lehmann & Voss is colour adjustment for high temperature thermoplastics, on the one hand to achieve pleasing design and on the other hand to more reliably identify similar injection moulded parts. Using demanding blending techniques it is possible to supplement the characteristic spectrum of the semi-crystalline polymer matrix of the compoun...

Kunststoffe international, 2005-11-21, Compounds and Masterbatches
...rs quite simple: polymer manufacturers produce the base materials in large volumes. These are then modified to produce individual polymer systems with the assistance of compounders and masterbatch producers. Manufacturers in the Triad Compounders achieve the desired product properties by incorporating the required ingredients, such as colorants (dyes and/or pigments) additives or fillers, into the polymer. The compound thus obtained is processed to produce the final article and, if the process...

Kunststoffe international, 2005-11-21, Concave Structures for the First Time
... mm. To produce this component, carbon-fiber-reinforced PEEK tapes measuring 5 mm x 0.2 were laid on a suitably contoured mold at a speed of 8 m/min. By further development of machine technology and suitable process control, it has been possible to achieve reversible adhesion of the first laminate layer to the mold surface. On completion of the production process, the part can be removed from the mold without any problem. This new development represents an important milestone in the production o...

Kunststoffe international, 2005-11-21, Conduits for Fibre-optic Cables
...eratures. The performance of older machines not yet fitted with current grooved-bushing and barrier-screw geometries can be increased by retrofitting the appropriate processing units. With more efficient grooved bushings, higher specific outputs are achieved. The higher screw torque required for this can be obtained by changing the gear reduction ratio. Assuming the rating of the drive motor remains unchanged, considerably improved melt quality is attained at lower screw speed. Through the lower...

Kunststoffe international, 2005-11-21, Consumer Protection: Migration Models for the Assessment of Plastic Products
...f the past few decades, these processes have not been treated in a uniform manner with respect to a diffusion-specific property of the polymer matrix P. It is only with the aid of a substance constant of this type that it will be possible to achieve a quantitative estimate of the diffusion rate as a function of the polymer matrix used and also a comparison of the different plastics. This is why the development of a model for estimating migration processes was focused on the estimate of diffusion...

Kunststoffe international, 2005-11-21, Continue to Improve Productivity and Quality
...ormations into account (Fig. 4B). The final result is the 3D geometry of the CAD designed clamping lever (Fig. 4C), the mass of which was reduced through the optimisation. High Performance Blowing Systems Today high performance blowing systems achieve amazing production results. At the NPE in Chicago this year Bekum Maschinenfabriken GmbH, Berlin/Germany, presented a new high performance blowing system. The BM-905 D produces a 400 ml three layer bottle in HDPE in 20 cavities with an output of ...

Kunststoffe international, 2005-11-21, Control Functions with Artificial Intelligence
...a few milliseconds. The complex control operations of the injection moulding machine are assisted by master control functions with artificial intelligence. The Electromechanical Drive Concept An important factor in the level of control quality is achieved by carefully matched drive and control components. This is guaranteed at Fanuc, since all components come from the same company (Fig.1). Fanuc have supplied the vast majority of electric machines now in production world-wide with over 13500 ...

Kunststoffe international, 2005-11-21, Controlling Injection Moulding Processes in Real Time
...he injection moulding process is then no longer controlled exclusively by the injection moulding machine. There are still certain restrictions imposed on the control of the cavity-filling process today. Despite the vast improvements that have been achieved in the open and closed-loop control of injection moulding machines, injection moulding problems and faults repeatedly occur. Sink marks, warpage, deviations between theoretical and actual shrinkage, entrapped air, over-injection and weld lin...

Kunststoffe international, 2005-11-21, Cooling Time Reduction by Foam Injection Moulding: It Can Be Done Faster
Cooling Time Reduction by Foam Injection Moulding: It Can Be Done Faster Production time influences unit costs directly. A reduction in the production cycle time represents a cash saving. Processors can achieve this aim in principle by using foam injection moulding. This article presents the potentials of the process and the reasons for its improved efficiency over conventional non-foam injection moulding. Walter Michaeli, Sasan Habibi-Naini, Erhard Krampe If appropriately employed, the ch...

Kunststoffe international, 2005-11-21, Cosmetics Packaging: Trend towards Transparency
...ew development from DuPont in the area of coextrusion blow moulding is that of thick-wall technology, a patent for which has been applied for. Together with its partner Crown Raku, Rastatt/Germany, DuPont uses Surlyn to cost-efficiently achieve impressive decorative effects on tubs and bottles which are similar to glass and which might not even be achievable with glass. A functional inner layer appropriate to the contents is combined with a thick-wall outer layer, which optimises properties such...

Kunststoffe international, 2005-11-21, Cost Efficiency and Innovations
...of the overall sales of some EUR 36 billion and roughly a quarter of the overall result of some EUR 3.4 billion. With cost-efficient plant and processes, further developed specialities and a simultaneous global presence, the division is intending to achieve disproportionately high growth over the next few years. Investment of EUR 2.5 billion is planned for the five years to come. The BASF Group as a whole has set itself the target of increasing its operative result by an average of 10 % over t...

Kunststoffe international, 2005-11-21, Cost-effective Modifier for Tailor-made Properties
...gh efficiency of ElvaloyAC in low additions by weight. The graph also shows just as clearly the superiority of modifiers such as Elvaloy PTW (a terpolymer of ethylene, butyl acrylate and glycidyl methacrylate) when high additions are required to achieve super-tough properties. Heterogeneity is the Key Until now, ethylene-acrylate copolymers have been manufactured in high-pressure autoclaves, in which the raw materials are thoroughly mixed to create a very uniform product. The new copolymers, o...

Kunststoffe international, 2005-11-21, Costs and Benefits: Recycling Plastics from Electrical and Electronic Products
...lastics, but the discrimination threshold is only in the region of 0.02g/cm3. In addition, additives, fillers and adhering contaminants interfere with this method. Since the densities of many polymers overlap, product purity >90% is difficult to achieve with such gravity-based processes. Calculation on a Full-cost Basis The cost calculations use typical assumptions for long-term-oriented operators on a full-cost basis. This means that long-term capital costs of about 7%, including real estate, ...

Kunststoffe international, 2005-11-21, Crash Simulation: Computer Modelling
...ation. With a newly developed numerical model, fibre-reinforced plastic components can be simulated far more realistically than with previously known methods. This will considerably improve virtual vehicle development. Stefan Glaser Andreas Wüst To achieve safe crash behaviour is one of the most challenging tasks in modern vehicle development. In addition to protecting just the occupants, increasing importance has been attached in recent years to protecting other people involved in crashes. In p...

Kunststoffe international, 2005-11-21, Custom-tailored Engineering Materials: Polyphenylene Ether (PPE)
...problems associated with moisture uptake and reduced dimensional stability. Since the discrete phases of PPE and PA are not miscible, compatibilisation technology is employed to improve the bonding forces, optimise the properties of the alloy and achieve a stable morphology [1, 12, 13]. The continuous PA phase of (PPE+PA) alloys provides good chemical resistance and processability. PPE is present as a disperse phase of finely distributed particles (Fig. 4). It acts as an organic filler that redu...

Kunststoffe international, 2005-11-21, Cutting Costs by Insert Moulding
... reliably by humans because of the small dimensions of the components, - the high weight of the parts to be moved, such as mould inserts, is too much for one operator, - injection moulding of special materials requires a high degree of continuity to achieve a stable process, - competitive pressure is forcing low unit costs and the only other alternative is to relocate production in a low-wage country, - the injection moulding machine cannot be operated by humans because mould temperatures are to...

Kunststoffe international, 2005-11-21, Dashboards Meet Highest Requirements
...lity specifications. With the continuing increase in the level of car quality expectations, aesthetic requirements as defined by terms such as "touch" and "quality perception" play an important role. Of course the materials used to achieve these ambitious aims must also satisfy the price requirements of the automotive industry. Generally speaking, only the price/performance ratio can be the deciding factor in prudent and responsible material selection. Decorative Materials and P...

Kunststoffe international, 2005-11-21, Decoration on the Front, Attachments on the Rear
...evelopment of in-mould decoration by injection moulding and compression moulding has brought a decisive increase in the quality and comfort of vehicle interiors. At the same time, it has proved possible to rationalise production of the parts and to achieve a more environmentally-friendly production process by eliminating the laminating adhesive. Today, the geometry of parts used in the vehicle interior is frequently so complex that conventional production with subsequent lamination is no longer ...

Kunststoffe international, 2005-11-21, Decorative Surfaces in the Automotive Interior
... for this, since they allow a temperature control profile that does not stress either the mould or material. Hot-air and sand-bed systems are also used. Rotational and oscillatory movements of the mould carrier and continuous heat supply are used to achieve a uniform layer of slush powder on the mould surface and continuous film formation of the material under process conditions that are as constant as possible. In the subsequent foaming process, the backing part and the TPU instrument panel ski...

Kunststoffe international, 2005-11-21, Defect-Free Microstructures
...hange in shrinkage of the degraded resin. Damage to the microstructure during ejection is a consequence of this material change (Fig. 3). After injection, the mould is cooled to a temperature that permits defect-free ejection of the moulded part. To achieve this, a combination of electric heating with oil- or water-based mould temperature control is often encountered in addition to a purely oil-based variotherm process. Defect-free replication of microstructures (Fig. 4) is possible only if, pri...

Kunststoffe international, 2005-11-21, Details of Economic Development: High-density Polyethylene (PE-HD)
...btropical fruits), there has been a concentration on producers in Southern Europe. Heavy pressure on the prices of ready-made sacks and nets (Fig. 7) is driving efforts to reduce the weight of the nets. The low tape titers needed to achieve this make high demands on the quality consistency of modern tape materials. The sluggish development in the construction industry is hindering continuous growth in the field of protective tarpaulins etc. In the sports and leisure segment, good development pot...

Kunststoffe international, 2005-11-21, Development and Trends: Plastics – a Mature Industry?
...or the desired properties through design of the polymer structure is becoming closer to reality from year to year. With less well-known, inexpensive building blocks and efficient technologies, and with intelligent design, we can quickly and easily achieve the solutions that the market requires. The Author Prof. Dr. Franz Brandstetter is head of polymer research at BASF AG, Ludwigshafen/Germany. Title photo. Superlative for engine building: 800 kg, 460 horsepower, and with 12 litre capacity, th...

Kunststoffe international, 2005-11-21, Development History of Plastics: Growth through Changing Times
... (Table2). The rapid growth of the UK plastics export trade is also interesting to note, and is surely confirmation of that country’s scientific and technical achievements in the field of polymers. In terms of production volume, the USA took the lead a long time ago (Table3). Its share of world production in 1950 was more than 65% (1951: 62%), followed by the UK with nearly 9% (1951: 11%) and the two German states, which together accounted for 8% (1951: 12%). Thermoplastics Win Through – 1950 t...

Kunststoffe international, 2005-11-21, Development Strategy and Environmental Protection: DuPont - Growing with Engineering Plastics
...of DuPont, recorded sales of 5.4 billion USD in 2003, 9% more than in the previous year," according to Terry Caloghiris, Vice-president and General Manager of the Engineering Polymers (EP) Division, at an advance press conference for K2004. EP achieved about half of its sales with product applications in the automotive industry. The remainder was divided between the electrical and electronics industry, general industry and consumer goods. To step up growth in engineering plastics, EP followe...

Kunststoffe international, 2005-11-21, Development Trends: Extrusion Blow-moulded Automotive Components
... production flexibility and a keen price/performance ratio. Only blow moulding companies with the initiative and the ability to position their design right in the area of construction have a chance to supply directly to the customer. In order to achieve this, the suppliers need to develop CAD concepts, which are based on their customers’ systems, implement project management schedules to meet mostly tight customer deadlines, and they require a good information management to recognise problems an...

Kunststoffe international, 2005-11-21, Dies for Multi-Layer Pipe Extrusion
...trusion dies with spiral mandrel distributors, and in most respects are significantly better than other die types such as spider-type dies, dies with spider-leg distribution and lattice basket-type dies. Simulation Computer simulations are used to achieve correct dimensioning of the flow channels - from the extruder to the die orifice. For conventional one-component flows in circular channels and in annular and slit dies, it is sufficient to use simple one-dimensional models and equations, ass...

Kunststoffe international, 2005-11-21, Direct Compounding: New Directions in Plastics Processing
... the variety of specific requirements. What are needed, though, are not only expensive specialty products. Depending on the application, these can be produced by blending in polymer fillers, and the properties desired in the end products are achieved at a minimally satisfactory level for reasonable costs. These methods are known already to many processors who mix the components while metering into the extruder. This is the first step on the path to direct extrusion. Compounding at independent co...

Kunststoffe international, 2005-11-21, Double Belt Plants: Flexible Production of Various Insulation Panels
...uisite for Cost-efficient Production If such a complex and expensive system is to be operated in a cost-efficient manner, it is essential to keep the stoppage time required for production switchovers as short as possible. To achieve this aim, the control system (which networks the sequence controls for the different parts of the plant) has a higher-ranking process control level above it (Fig.5). This takes charge of raw material management, including administration of the coil store, which has b...

Kunststoffe international, 2005-11-21, Driving the Automotive Industry: Engineering Elastomers
...ber manufacturers [2 to 4] is set to continue in the near future. The joint venture between DuPont and Dow Chemical (Dow DuPont Elastomers) formed in 1996 has recently been dissolved (in July 2005). The expected doubling of sales by 2001 was not achieved. In fact, there was only a slight increase in sales over 1996. These elastomer activities have since been continued in the form of a wholly owned DuPont subsidiary renamed DuPont Performance Elastomers (DPPE). At the end of 2003, Polimeri Europa...

Kunststoffe international, 2005-11-21, Drying, Conveying and Dosing of PET
...etric dosing and mixing systems for compounding materials and transferring them to the main extruder and coextruder, and - recycling the regrind from the coextrusion process. The most important task is to compound the PET in the drying system to achieve the properties necessary for processing, and to ensure that these properties do not change during the conveying and dosing operations. Furthermore, the individual formulation components must be dosed extremely accurately. Product changeover time...

Kunststoffe international, 2005-11-21, Dynamic Growth: Liquid Crystal Polymers (LCP)
...ymers). These companies focus their attention on not only the feasibility of the project but also an efficient production process and the resultant lower manufacturing costs. This is a further advantage of LCPs, since the processing benefits help to achieve lower piece part costs when producing larger quantities in spite of the higher price per kilogram. Suppliers and Capacities Since their introduction to the market in the mid-1980s, LCPs have experienced rapid growth, with annual growth rate...

Kunststoffe international, 2005-11-21, Easy and Reliable Demoulding
...ig. 5), a two-component mould is used to process ABS and TEEE natural (Hytrel). The demands made on the quality of the finish are very high indeed. The uniform structure must be perfectly retained because the part will be subsequently painted. To achieve a high level of process reliability, a layer of electroless nickel PTFE was applied to the mould cavities. This enabled the demoulding forces to be lowered and was no problem at all for the subsequent painting. Due to the deposition mechanism, t...

Kunststoffe international, 2005-11-21, Easy-opening Concepts: Easy-opening Sterile Packaging
...the form of cohesive failure inside the blended, and hence mechanically ‘weaker’, sealing layer. Through precise coordination of the rheological and mechanical properties of the polymers that are used for the compound, it is possible to achieve a very low tear propagation strength with this concept. In this way, undesirable fibre formation can be reliably avoided, i.e. no particles will be torn out of the sealing surface. Burst-Peel The term burst peel describes a concept in which the delamin...

Kunststoffe international, 2005-11-21, Ecoefficiency: Plastics in Politics and Practice
...ffer in a selective application of use and/or disposal are characteristic. Tailor-made Applications Today’s marketable biologically degradable materials are characterised by the fact that they are tailor-made for the respective application. They achieve an optimal compromise between technical performance profile and good biological degradability. Example applications can be found in the most diverse fields. Resorbable implants in medical technology (Fig.1) can render a second operation superf...

Kunststoffe international, 2005-11-21, Ecological Beneficial Composites
...ainer Alex, Reutlingen/Germany Especially high quality materials can be produced using domestic natural fibres. Therefore existing procedures and formulations are being adapted to the requirements of natural fibres. It has thereby been possible to achieve the characteristics profile of glass fibre reinforced plastics and sometimes to even exceed it. Especially high quality materials can be produced using domestic natural fibres. Therefore existing procedures and formulations are being adapte...

Kunststoffe international, 2005-11-21, Economic Compounding: Nanocomposites
...ic surface area determines the characteristic properties of the nanocomposites. For example: - flexural strength, tensile strength and elastic modulus can be increased without any significant loss of toughness, - improved barrier properties can be achieved without reduction in transparency or surface quality, - cable sheathing compounds can meet the requirements of fire rating UL94V0 with significantly reduced addition of aluminum trihydrate (ATH), i.e. improved processability and better mechani...

Kunststoffe international, 2005-11-21, Economic PVC Pelletisation
...born, Munich/Germany Economic production of PVC pellets requires an optimised plant concept. Processors demand reliable production reproducibility and place importance on processing the widest spectrum of materials with maximum quality. This can be achieved with carefully matched processing units, allowing full control over the process. PVC pellets are easier to store and transport than powder dry blends. They absorb much less moisture on storage. Their feed behaviour to the extruder is much bet...

Kunststoffe international, 2005-11-21, Economical in Long Series
...res are dry wound and aligned exactly according to the load the component will later carry. - The thermoplastic pipe with reinforcement material wound on it is then inserted into the centrifuge mould. In this way an appropriate fibre orientation is achieved in the centrifuge mould. - The thermoplastic core pipe is heated during slow rotation until the thermoplastic material is melted and functions as matrix material. - The actual centrifugation procedure takes place in the fourth step. The rotat...

Kunststoffe international, 2005-11-21, Economical Production of Barrier Film
...rably used for engineering polymers because of their broader range of application. They can also reliably process critical substances like EVOH, polyamide 6, PET or COC in different thicknesses. Apart from this, extruders with a smooth feed section achieve better homogenisation of the melt because the pressure flow acts against the drag flow and the speeds are higher at the same throughput. Nevertheless, in all extruders, mixing sections should be used that homogenise the melt perfectly with low...

Kunststoffe international, 2005-11-21, Economical Production of PU Parts
...ffness and short demoulding time, and tough flash, and a high tolerance to fluctuations in environmental and process conditions. To meet this range of requirements, the chemical reaction must be largely completed at the time of demoulding. This was achieved by converting the Bayflex 110 "one-shot" systems to the Bayflex 180 prepolymer system (Fig. 4). When Bayflex 110 was used, two reactions had to take place in the mould virtually simultaneously. The long-chain, relatively slowreacting ...

Kunststoffe international, 2005-11-21, Editorial: Buy Recommendation
...s and on providing sufficient funds to ensure a constant readiness to invest, rather than paying consideration to the shareholder. The sector's international orientation is also being rewarded, since the German machinery sector has managed to achieve an export ratio in excess of 80% for the very first time this year.

Kunststoffe international, 2005-11-21, Editorial: Experience as Added Value
...petition in future, as a result of changes in society and expanding new markets". He feels that the route to success lies in "technology leadership, strict cost management and, above all, attractive cars at competitive prices“. In a bid to achieve this aim, car manufacturers are increasingly calling upon their suppliers to act as development partners. System suppliers, in particular, are expected to prefinance development work and to tailor it to new models and variants as they are intro...

Kunststoffe international, 2005-11-21, Editorial: Nothing Comes from Nothing
...cycles for new car models, coupled with restructuring and rationalisation measures, which are evidently proving to be too much for many of the automotive suppliers. Supplier companies are cutting back on their development departments in a bid to achieve the necessary cost savings and, through their constant internal reorganisation, are destroying the small, informal groups which frequently provided mutual assistance to each other and came up with good ideas. Precisely the German car manufacturer...

Kunststoffe international, 2005-11-21, Effective and Cost-Saving
... - cleaning of inaccessible areas. In the present case, burnt-on rubber residues, oxides and release agents had to be removed from rubber-processing moulds. These steel precision moulds require absolute purity, which would be virtually impossible to achieve with manual cleaning. In addition to the standard units, the company has developed flexible modular systems. The modular units are suitable for combination of different individual components, such as the untrasonic cleaning modules and rinsin...

Kunststoffe international, 2005-11-21, Efficiency in a Highly Compact Space
... highly positive course of business at the Steiner Group with its international presence. With annual growth rates running in two figures, Steiner Industries AG recorded sales of approximately EUR 130 million in the 2000 financial year. These were achieved by four companies operating within the group. The group's two product lines are being produced on the newly-purchased machines. These are garden furniture in a wide range of colours and designs (Fig. 2) and also the so-called Steco-Box (Fi...

Kunststoffe international, 2005-11-21, Electrical - But Safe!
...s out to provide some basic information. The European Safety Concept With the Single European Act (EEA) in 1987, the EEC Treaty from 1957 was changed, and the introduction of the Single European Market was legally fixed for December 31, 1992. To achieve this political aim, the legal and administration regulations have been gradually harmonised in the various sectors of economic life. The goal is to remove all the technical trade barriers that exist in the member states due to differing technic...

Kunststoffe international, 2005-11-21, Electronic Components and Displays: Intrinsically Conductive Polymers
...g polymers, there are also electrically conductive polymers, where the group of conductive polymers must be divided into polymer compounds with conductive additives and the group of intrinsically conductive polymers (ICP). While conductive compounds achieve their conductive properties through addition of conductive additives such as metal particles or conductive carbon black, intrinsically conductive polymers do not require the addition of any additive whatsoever. From Structure to Commercial Ap...

Kunststoffe international, 2005-11-21, Engineering Network: Additional Knowledge Instead of Competition
...tance, the thickness of the inserts is 500µm. FME analyses or feasibility studies are compiled in order to establish how to conceal the edges at the end. The problem with big parts lies in ensuring a constant shrinkage. If it proves impossible to achieve this, then the number of rejects will rise. Also, there is no extrusion company that will guarantee a perfectly constant material quality on a permanent basis. One frequent source of annoyance is concealed defects (such as specks in the roll, so...

Kunststoffe international, 2005-11-21, Engineering Plastics as a Growth Market
...rk is also being carried out on this project within the Engineering Plastics Business Unit. The aim is to make processes safer and more effective and thus to lower the error rate. Substitution-potential Far from Being Exhausted DuPont is aiming to achieve the two-digit growth target in Engineering Plastics not least through various innovative applications. The company still sees considerable substitution-potential with parts still produced from metal or thermoset materials. "To date, we ha...

Kunststoffe international, 2005-11-21, Engineering Plastics: Products for Innovative Processes
...as K224-HWXG6, a 30% black-coloured, glass-fibre-reinforced grade. Because of the high laser-energy transmission of the PA6 base polymer (70% of a 1064nm-Nd-YAG laser), shorter cycle times, more complex geometries and lower section thickness can be achieved. BASF has launched a special grade for the laser direct structuring process (LDS) under the trade name Ultramid T KR 4380 LS. This is a specially tailored compound for the LDS process with 30% glass fibres and optimum properties in terms of ...

Kunststoffe international, 2005-11-21, Europe is the Largest Market: Polyaryletherketones (PAEK)
...rope is the Largest Market. There is sustained growth in the use of high-performance plastics from the PAEK family in all sectors of industry. The balanced, high-quality property profile of these materials enables product developers and designers to achieve innovative solutions in response to the constant demand for cost saving, functional optimisation, weight reduction, longer service life and maximum safety and comfort. The world’s largest quantities of polyaryletherketones are currently bein...

Kunststoffe international, 2005-11-21, Everything Revolves Around the Disc
...ping force. DVD-R substrates are not made by direct injection, but by the so-called coining process. Hereby the melt is injected before the mould is fully closed and closing is slowly completed after the mould filling process. The method permits to achieve an excellent reproduction and dimensional accuracy of the groove within nanometres, and this with a low birefringence and a high deflection temperature. Table 1 shows that the storage capacities of all re-recordable media can be roughly calcul...

Kunststoffe international, 2005-11-21, Exactly Suited Material Preparation: Reliable Use of PET Flakes
...increasing admixture of PET flakes it is advisable to dry and supply both materials separately by way of constant temperature metering systems for the processing machine. Thus production flexibility and quick reaction to quality changes can be achieved. The schematic representation (Fig.4) shows only one of several realisation possibilities for storing, moving, crystallising, drying and metering new material and PET flakes optimally. This is because the potential difficulties when preparing mate...

Kunststoffe international, 2005-11-21, Exhaust-Air Purification in Laser Technology
...rocess should be as small as possible. - The pollutant removal rate should be high enough that the purified air can be returned to the workplace. - The design of the treatment unit should allow it to be integrated into the laser processing unit. To achieve these aims, a completely novel principle was developed and tested in various applications. The pollutants produced during processing are intercepted as close as possible to the operating position. In some cases, local extractors can be used th...

Kunststoffe international, 2005-11-21, Expandable Thermoplastic Polyurethanes: On Light Soles
...lling permits considerably shorter cycle times than with compact TPU, and the perfectly matched components of the TPU system guarantee a broad processing window without any signs of void formation. An optimised mould design is essential in order to achieve low densities and trouble-free production with Elastollan Light. High levels of shear should be avoided in the injection unit and the mould during processing. This can be achieved by employing generously-dimensioned runner cross-sections (diam...

Kunststoffe international, 2005-11-21, Expansion Injection Moulding: Amazingly Thin
...n Moulding Amazingly Thin Expansion Injection Moulding. According to the state of the art, thin-wall injection moulding requires the injection unit to be supported by a hydraulic accumulator. But without a hydraulic accumulator greater precision is achieved in the process technology, energy consumption is lower and amazingly thin walls can be produced. The new state of the art is called "X-Melt", the expansion injection moulding process developed by Engel. It is all made possible by the...

Kunststoffe international, 2005-11-21, Exterior Vehicle Body Parts: Films instead of Painting?
...component size increases, particularly if film coaters purchase raw materials and semi-finished products from different suppliers. In 1997, the use of coextruded films for back-injection moulding was reported for the first time [2, 3]. These films achieved a significant reduction in manufacturing costs, while providing higher surface hardness and inherent polishability due to the use of a PMMA top layer on a carrier layer of LuranS (ASA and ASA+PC). At K’98 in Düsseldorf/Germany, BASF AG, along ...

Kunststoffe international, 2005-11-21, Extremely Fast
...olyetheramines (grade: PC AMINE DA 2000) with the isocyanate prepolymers is however too fast for some applications so that, particularly in the area of pourable elastomers, additives have to be used. They are intended to reduce the reaction rate and achieve longer flow times. In the case of spray applications, a rapid increase in viscosity and rapid cure are required. To achieve smooth spray surfaces, good flowability of the system and good adhesion of the individual spray coats to each other or...

Kunststoffe international, 2005-11-21, Extrusion Technology of the Future
...ment work is now concentrating on swarf-free cutting by means of specially adapted knife-cutters (Fig. 3). For extrudates with a simple cross-section, membrane nozzles have been developed, which are used in film production with short payback time to achieve cost savings [1]. Developers and users are required to make this or similar technologies available for general extrusion. Increasing Productivity In view of the greater cost pressure, increased output in order to achieve higher productivity...

Kunststoffe international, 2005-11-21, Extrusion: Automation – Right Down the Line
... For the main drive unit of the extruder, the trend is moving increasingly away from DC motors to brushless three-phase motors because they require no maintenance. The latest developments in motor technology are direct high-torque motors that achieve very high torque at low speeds (Fig.5). They make it possible to power the extruder without a gearbox. This also eliminates speed fluctuations caused by gear-play and cuts out the downtimes due to maintenance work on the gearbox. For the main drive...

Kunststoffe international, 2005-11-21, Fast and Reliable
....5x1.5mm². For the contour welding, the laser head was attached to the arm of a 6-axis robot (grade: RV-4A, manufacturer: Mitsubishi Electrics, Ratingen/Germany). This system can be more or less freely programmed via a PC system and is able to achieve travel velocities of up to 3000 mm/s. To guarantee a reproducible welding process, the joining device was designed in accordance with the geometry of the two components. In addition, this device also had the task of generating, via a pneumatic...

Kunststoffe international, 2005-11-21, Fast Product Development
...g RP and RT. The main reason for this is the lack of information on the capabilities of these methods and also on their availability and cost-efficiency. Constant further developments, particularly in the field of rapid tooling, make it difficult to achieve a comprehensive overview and to select the right process for the application in question. Since these problems are also being encountered in other EU countries, the "Club RP" project was set up with the aim of establishing an EU-wide ...

Kunststoffe international, 2005-11-21, Fewer Production Stages, Shorter Cycles
...er from "slipping" of the initially injected melt. The decoforming process developed by Krauss-Maffei is notable for the fact that the mould containing the decor material closes completely in the first step. When injection starts, the mould achieves the required compression gap. This causes the melt to adhere to the decor side, where it is held in place by the inflowing polymer melt and does not fall down between the mould halves. Through the closing movement of the mould, the melt cake ...

Kunststoffe international, 2005-11-21, Fibre Composite Parts: Automated Preform-RTM Production
...Preform-RTM Production Experience acquired in automated textile engineering and plastics technology, coupled with software developments that can be implemented in different branches of industry, make it possible to optimize automated processes and achieve considerable savings potential. Thanks to the many years’ experience acquired in the mass production of textile clothing and the high market volume involved, these production processes are now run in an extensively automated and cost-effici...

Kunststoffe international, 2005-11-21, Fibre Composites in the Global Limelight
... 5/lb) forecast many years ago by the Zoltek company of St. Louis/USA, is not feasible as yet however. At present, the price of reinforcing fibres is still in the DM 28/kg (approx. US$ 7/lb) range. The company is pursuing two strategies in order to achieve the set targets: first of all, work is underway on the development of its own precursor and, secondly, the requisite market volume of applications is to be extended by means of forward integration, i. e. through the acquisition of component pr...

Kunststoffe international, 2005-11-21, Fibre Composites: Bonding Automotive Bodies
...ibre-reinforced plastics also offer relatively high strength and stiffness, combined with low weight. They are highly corrosion resistant and permit a high degree of freedom of design, which, if possible for metals, would be extremely expensive to achieve [2]. For example, the rear door of the Mercedes-Benz C Class Coupé owes its complex form to an innovative plastics solution using SMC (sheet moulding compound) [3]. Fibre composites, such as SMC or GMT (glass-mat-reinforced thermoplastics) are ...

Kunststoffe international, 2005-11-21, Fibre Reinforced Plastics: Tailor-made Reinforcing Textiles
Fibre Reinforced Plastics: Tailor-made Reinforcing Textiles Textile semi-finished products for fibre composites can be made up by employing conventional sewing techniques. Special mechanical properties can be achieved in sewn and resin-impregnated parts in this way. Kai Klopp, Thomas Gries Due to their complex nature, fibre reinforced plastics (FRP) have a very high potential for solving specific strength problems. Continuous fibre reinforced plastics are employed in aeronautics and aerosp...

Kunststoffe international, 2005-11-21, Fibre-reinforced Plastics: Lightweight and Corrosion-resistant
... both the manufacturing costs and the damage tolerance vis-à-vis stressing under the action of force must correspond approximately to those for a metal construction. Johannes Wolfrum As things stand today, low-cost composite materials can only be achieved with glass fibre reinforcement. Considerable progress has been made in the textile engineering of reinforcement fibres over the past few years, and it is now possible to place parallel reinforcement threads in layers on top of each other at v...

Kunststoffe international, 2005-11-21, Fibre-reinforced Plastics: Naturally Better
...bre-reinforced Plastics. With hemp, sisal etc. in a polyurethane matrix, large-format mouldings can be produced that are on a par with their glass fibre-reinforced equivalents. In the ideal case, the lower intrinsic weight of natural fibres can even achieve weight savings of up to 15%. However, so far there have been restrictions due to the handling of natural fibre mats. The development of the NFI process now allows more economical natural fibre rovings to be used in a spray layup process. Wolf...

Kunststoffe international, 2005-11-21, Film Processing: Dynamic Control of Roll Temperatures
...of Conventional Fluid-based Temperature Control The experiments show that with conventional fluid-based control of the roll temperature, satisfactory embossing is not possible in many cases. By way of example, Fig. 1 shows the embossing results achieved in a PMMA melt with the above-mentioned brass ring. The effect of the roll temperature ]w on the embossing is quite clear. Even slight variations of the roll temperature have a significant effect on flow of the material into the embossing pattern...

Kunststoffe international, 2005-11-21, Flame Retardants
...osphate) for (PC+ABS) as well as (HIPS+PPE) blends. Adeka is additionally in the process of developing T-946, a halogen-free flame retardant based on phosphorus and nitrogen for polypropylene homopolymers and copolymers; this will achieve a UL 94 V0 rating at 1.6mm. Süd-Chemie AG, Moosburg/Germany, supplies nanocomposites on the basis of layered silicate (montmorillonite), with layers that are expanded with long-chain carboxylic acids and their derivatives. Nanofil 15, for example, is a product ...

Kunststoffe international, 2005-11-21, Flame Retardants: Flame-retardant Epoxy Resins
Transportation Flame-retardant Epoxy Resins Flame Retardants. While phosphorus-based flame retardants in epoxy resins often showed inadequate processing and material properties, recent work has succeeded in developing phosphorus-containing resins, curing agents and additives with significantly improved properties. Based on an organophosphorus compound, halogen-free, flame resistant epoxy resin systems can now be produced with good mechanical properties. There is no let up in the trend towards u...

Kunststoffe international, 2005-11-21, Flame Retardants: Growing Demand
... 1312 have been specially developed for glass-fibre reinforced polyamides. Both flame retardants are noted for their high CTI (Comparative Tracking Index) of 600 volts and their low compound density. Only small amounts need to be added in order to achieve fire-retardant classifications such as UL 94 V0 or GWFI 960°C (Glow Wire Flammability Index). Clariant's range also includes additional flame retardants based on other organic phosphorus compounds, ammonium polyphosphate and red phosphorus....

Kunststoffe international, 2005-11-21, Flame-Resistant GRP Systems
...dispersing additives are added in a fine balance to impart the necessary level of filler loading in the various systems. Naturally, because the various regulatory standards vary, different formulations are needed for meeting their specifications. To achieve S4, SR2 and ST2 status in German standard DIN 5510, which itself is waning in importance, a formulation for SMC only needs to have the composition set out in Table 1. Pultrusion formulations filled with aluminium hydroxide also achieve S4, SR...

Kunststoffe international, 2005-11-21, Flame-retardant Curing
...dancy standards for different final products and countries (Table 1) [1, 2]. In general, a distinction is made between reactive and non-reactive flame retardants (Table 2). Non-reactive flame retardants require high filler contents in the matrix to achieve sufficient activity, but cause significant reductions in mechanical properties. The trend is therefore towards reactive flame retardants that must be chemically incorporated into the network structure of thermosets, without reducing mechanical...

Kunststoffe international, 2005-11-21, Flat-film Extrusion Lines
...and higher production capacity due to the more intensive melt cooling. For this reason, composite films with PP outer layers dominate the market. However, as a result of the extrusion technology with slot dies, only monoaxial film orientation can be achieved, which can prove a disadvantage during further processing into outer packaging because of the tendency of the films to split in certain circumstances. Single-screw Extruders In recent years, the requirements that a film plant has to meet i...

Kunststoffe international, 2005-11-21, Flex-ring Dies: Improved Wall-thickness Distribution of the Preform during Blow Moulding
...ial wall-thickness control, so that a compromise must always be made regarding the optimum wall-thickness distribution in the two directions. If the part to be produced has a very complex geometry, an optimum wall thickness distribution can only be achieved by a dynamic change in the thickness of the preform in the axial and radial direction. In addition to the programmable wall-thickness control (PWDS), which has been in use for years, parts manufacturers now have an interesting alternative for...

Kunststoffe international, 2005-11-21, Flexible and Inexpensive
...other market sectors such as sport and leisure, water and chemical, and also industrial is rapidly increasing. Processing PP-LGF Mechanical shear needs to be kept to a minimum in order to reduce fibre breakage to an acceptable level. This can be achieved by keeping the screw speed and back pressure low, but still high enough to achieve optimum distribution and homogeneity of the fibres in the matrix. A compromise has to be found between fibre retention on the one hand and fibre distribution a...

Kunststoffe international, 2005-11-21, Fluid Injection Technique: Understanding Residual Wall Thickness
...arks, the delay times should be as short as possible with the short-shot technique, so that only very thin solidified surface layers can form. Longer residence times are possible with the overflow technique and to a limited degree can be used to achieve a larger RWT. To date, the effects of the rheological material properties on the RWT have not been investigated systematically for the water-assist technique; the published investigations for the gas-assist technique sometimes contradict each oth...

Kunststoffe international, 2005-11-21, Foam Injection Moulding: It's Not the Bubble Size that Counts
... characteristic values. The latest investigations show that microcellular foamed parts even possess poorer mechanical properties than fine-cellular foam parts with an integral foam structure. By foaming thermoplastics, it is frequently possible to achieve a reduction in the part weight. In the case of technical parts with a wall thickness of between 1 and 3.5mm, however, the material savings are generally limited to a maximum of 15%. If the weight is reduced any further, the mechanical propert...

Kunststoffe international, 2005-11-21, Food Packaging: PET Sheet without Predrying
...fication from Battenfeld, which will be installed in the middle of next year. This line will manufacture a product in continuous operation. Since product conversion and the associated machine downtimes will be eliminated, the processor expects to achieve a line capacity of an impressive 15000t/year. His sheet production capacity should be increased by a further 50%. Manufacturer Battenfeld Extrusionstechnik GmbH Königstrasse 53 D-32547 Bad Oeynhausen Germany Phone +49 (0) 57 31/2 42-0 Fax +49 ...

Kunststoffe international, 2005-11-21, For the Car of Tomorrow
...tomotive glazing depends on the development of a special coating that both satisfies the abrasion resistance specifications which this demanding application imposes and provides vital protection against physical and chemical corrosion. This has been achieved by combining two processes developed by Bayer and GE Plastics, the parent companies of Exatec. This company is dedicated in Europe and the USA to developing, manufacturing and selling PC glazing. The new product (grade: ExatecPlus) is notabl...

Kunststoffe international, 2005-11-21, Forced Pneumatic Demoulding
...cted via an open eight-cavity hot runner system (6) with a sub-runner. Since the shoe only has the second component injected around part of its edge, there is no link between the area of second component on the lid and that on the shoe. In order to achieve equidistant flow paths, it was necessary to have two hot runner nozzles for the edge region of the shoe and two nozzles for the edge region and the film hinge on the lid. The nozzles are of different lengths in order to compensate for the heig...

Kunststoffe international, 2005-11-21, Formwork Elements: Building System with High Future Potential
... same system from different production locations without dimensional discrepancies. The construction units must be able to withstand harsh treatment on the building site. In addition a maximum degree of fusion of the EPS panels must be achieved so that the connections can withstand the concrete pressure when pouring. Quality inspections must follow production in order to guarantee production according to the building standards. Thus the mechanical strength between the EPS and the inserted parts,...

Kunststoffe international, 2005-11-21, Framework Principle: New Production Process for Fibre-reinforced Composite Components
...igher than those of LFT. This fact is emphasised still more in the component by the lower scatter of the unidirectionally oriented EF inserts and their excellent reproducibility. The considerable increase in flexural strength and flexural rigidity achieved by the insertion of EF profiles can be seen in the example of a U-shaped, ribbed test bar (Fig.6). The EF profile reinforcements were placed laterally in the two vertical walls. Even reinforcement of thermoplastics solely with long glass fibr...

Kunststoffe international, 2005-11-21, Friction Behaviour of Thermoplastics
...ed with this, particularly in [9]. Basic Principle of the Newly Developed Test Apparatus The aim of the test method that has been developed [10] is to simulate the described interactions and reproduction of the metal surface structure [11, 12]. To achieve this, the plastic must be heated so that it can flow sufficiently to wet the metal surface. In injection moulds, the polymer melt is injected into the mould under pressure. In the test apparatus on the other hand the injection moulded test sp...

Kunststoffe international, 2005-11-21, From the Idea to the Product
...very wide range of problems that accompany product development, together with the links that exist between the different problems. Low-melting Glass as a Filler In many cases, polymers by themselves are unable to fulfil the constant endeavours to achieve miniaturisation, coupled with a simultaneous demand for parts that offer a wide range of functions. Glass fibres, glass spheres and mineral fillers are generally added to the polymers in order to enhance their mechanical properties. One drawba...

Kunststoffe international, 2005-11-21, Full House: Innovative Systems Prove an Attraction
... (with a cavity pressure of around 100bar) which are suitable for the pressure and temperature-sensitive decorative materials. Taking the current state of the art, the best pressure and temperature distribution is achieved with injection compression moulding and integrated decoration compression moulding. In this latter process, the decoration is kept in place through the application of a vacuum, generally in the upper part of the mould. The lower half of the mould is filled via slot die while ...

Kunststoffe international, 2005-11-21, Functional Design: Acoustic and Design Concepts for the Engine Compartment
...ection gasoline engine, the 1.6l MPI multi-point indirect-injection engine and the 1.9l TDI pump jet diesel engine. With its 1.9 l TDI engine cover, Weber has succeeded in moving into the expanding diesel business. The big challenge here was to achieve a good combination between appealing design and effective noise insulation. Attractive Design, even in the Engine Compartment One of the car manufacturer's specifications was that the engine covers should have high-quality optical and tactile...

Kunststoffe international, 2005-11-21, Functional Plastics: Materials Research as Technical Investment
...echnology. The sales volume here is generated by the component or system, and not the material itself (Fig.2). In contrast to the development of a new polymer in which a new basic material is introduced for a number of new applications in order to achieve the sales volume required for amortisation, the requirement for a new functional material is usually defined by a single new application. The same applies in large part to nanoparticles such as carbon nanotubes in a plastic matrix. The basis f...

Kunststoffe international, 2005-11-21, Functionality is the Key Factor
...sisting of a cellular core and a solid smooth surface. This results in high strength properties and impact strength in combination with low weight and low wall thicknesses. It can also be used for complex moulding geometries which are difficult to achieve with thermoplastics. The smooth polyurethane surface is easy to clean, is chemically resistant (e. g. to detergents and disinfectants), and its basic structure also helps to insulate any noise made by the apparatus itself [13]. Production of M...

Kunststoffe international, 2005-11-21, Gas-assist Injection Moulding: GAIM: From the Design to Successful Application
...n, including the automotive industry, household applications and house building, the following were named as the most frequent difficulties: - gas penetrating the gate - the gas needle becoming soiled - the maximum gas bubble length not always being achieved, which results in sink marks with shorter gas bubbles - metering fluctuations causing flow marks in the residually-filled zone - dissimilar glossiness resulting through fluctuations in the amount of compound (shot weight) - finger effects oc...

Kunststoffe international, 2005-11-21, Gas-assisted Injection Moulding: Accurate Determination of the Injection Points
...Injection Points The first example, a thin-walled plate with a connected thick-walled region (Fig.3), is intended to illustrate that the above-formulated requirements for part filling and for the post-filled region cannot always be easily achieved for the application of gas-assisted injection moulding. Reproducible expansion of the gas is only possible in the connected thick-walled region. It takes place unidirectionally. As a result, for correct positioning of the melt injection point, after t...

Kunststoffe international, 2005-11-21, Gas-assisted Injection, Temperature Control, Foaming: Industrial Gases as Aids During Injection Moulding
...ogen usually suffices to cool the moulded product, but the requirement for additional cooling is growing because of increasing demands for reduced cycle times and the resultant increase in productivity. Lindes new technique with internal cooling achieves greater cooling through additional gas flow. After normal gas injection, the flow of nitrogen to the primary gas injector is interrupted and the injector is opened to the ambient air. Simultaneously, nitrogen is introduced through a second gas i...

Kunststoffe international, 2005-11-21, General-purpose Plastics: Appearance Ever More Important
...scale temperature fluctuations of up to 80°C. A new generation of random PP from Borealis makes it possible to employ durable pipe systems with thinner walls for hot and cold water delivery pipes. Cost savings of up to 13% per meter can be achieved in this way, making plastic pipe systems even more competitive by comparison with traditional materials. Borpact SG930MO is the name of an injection moulding grade of PP from Borealis which is formulated for deep-freeze applications. The transparent ...

Kunststoffe international, 2005-11-21, Glass Fibre Reinforced Components: On the Road to the Composite Car Body
...pproach to this project from the point of view of an expert in producing advanced composite structures rather than from that of a car designer. We had to fundamentally question the traditional techniques in car manufacturing to achieve optimal results.” Feasibility Data from Simulation The Ecolite team is pursuing an array of composite technologies with various materials, such as polyamide, PBT and polystyrene systems. First, they will be manufactured based on glass fibre reinforced materials ...

Kunststoffe international, 2005-11-21, Good is Not Enough: From Initial Idea to Successful Product
... appearance and feel as leather. And it was the social need for greater safety in road traffic that triggered the development of airbags. But how big is the playing field in which the innovation potential that enables our company to achieve profitable growth can move? Here, it is a question of finding a balance between high market attractiveness and an optimised cost-to-benefit ratio. In other words, we have to differentiate ourselves from our competitors in attractive markets. To fully exploit...

Kunststoffe international, 2005-11-21, Growing Profitably: BASF: "Offering Customers Clear Advantages"
Special BASF: "Offering Customers Clear Advantages" Growing Profitably. By clearly focusing on the business model of the future, reducing fixed costs and concentrating on profitable segments in partnership with customers, BASF plans to achieve continued successful growth in its plastics business. The aim is to earn a premium on the cost of capital. BASF intends to push ahead with the strategic development of its plastics business. This was made clear by Dr. John Feldmann, the BASF AG bo...

Kunststoffe international, 2005-11-21, Growth Market for Powder Injection Moulding
...s the flow properties of the polymer and can be processed as pellet stock by conventional injection moulding. The injection moulded part (green compact) is formed as with plastics injection moulding with more or less complicated injection moulds. To achieve the finished part, the binder is removed (known as "debindering") from the green compact, usually in a two-stage process, by the effect of heat and/or a chemical process. The resulting "brown compact" has approximately the sam...

Kunststoffe international, 2005-11-21, Hard-soft Composites with Metal Inserts: New Generation of Plastic-Metal Hybrids
...rt overmoulded with a soft thermoplastic (typical application of unreinforced polyamide) that is subsequently over-moulded with a fibre-reinforced thermoplastic in a 2-component injection moulding process [10]. The MCDS technology employed to achieve this represents a major advance over hybrid technology. Series Implementation Based on Analyses and Trials Various finite-element models were used during the research to analyse the characteristic structural elements of MCDS and the results were co...

Kunststoffe international, 2005-11-21, Headlamp Bonding: Warm Reactive Bonding
...eactive fusion adhesives or hot melts (RHM) and - humidity-reactive fusion adhesives or warm melts (RWM). Hot melt sealants based on butyl rubber are used as non-reactive systems. For rational manufacture of automobile headlamps it is necessary to achieve a durable connection without mechanical fixation, e.g. clips. At the same time a leakage test must be made as quality control after bonding. Single-component adhesives based on silicone do not fulfil all the wishes of the goal market. These pa...

Kunststoffe international, 2005-11-21, Healthy Sleep . . .
... only half the strength of the above-mentioned fibres and due to its higher elongation at break of over 10 % is less suitable for applications in GRP composite materials. In composite materials the fibres must be completely covered by the matrix to achieve good transfer of shear stresses between the fibres through the matrix. Here strong twisting of the fibres in the yarn is a limitation since the internal fibres of the yarn are shielded by the outside ones and are thus not wetted. Additionally ...

Kunststoffe international, 2005-11-21, Heat Management
...t attacked by fungi and microbes and have neutral biological effects [4]. They can be easily sawn and cut, facilitating the laying and assembly of made-to-measure insulating layers for all requirements. Thermal insulating materials of PU rigid foams achieve measured thermal insulation values of 0.019 to 0.024 W/(mK) - the thermal conductivity of air is 0.025 W/(mK)! However, the insulating effect of rigid foam insulating materials in buildings is generally assessed not according to the measured ...

Kunststoffe international, 2005-11-21, Heat Treatment: Drying with Infrared Radiation
... other safety materials from polyamide 66 (PA66). Coating them with silicone reduces surface friction and allows the material to unfold later in a fraction of a second. However, PA66 is hygroscopic, e.g. it draws water out of the environment and may achieve a humidity content from 3 to 5%. Before coating, this percentage has to be reduced to ensure that the silicone adheres well and to achieve the optimal surface quality of the tissue. The drying and preheating processes necessary for this proc...

Kunststoffe international, 2005-11-21, High Barrier: Nanoscalar Particles Enlarge Potential Applications
...ar fillers, to break up into smaller particles the nano-fillers present as nano-particles, so-called nano-clays, by dispersive mixing in order that the polymer melt may penetrate into the layer structure of the nano-fillers (intercalation) to achieve a very uniform distribution of the separated layers in the base material (exfoliation) by distributive mixing. After exfoliation, the nanoscalar fillers are 1/1000th the size of conventional micro-fillers and distributed more finely in the matrix as...

Kunststoffe international, 2005-11-21, High Fitting Accuracy
... and a lower coefficient of thermal expansion. Competitive price, throughput time: The BX prepreg system cures at low temperatures. The autoclave pressure needed to compact the laminate is 3.5 bar. At this pressure, a high surface quality is also achieved. The curing temperature and pressure thus permit the use of readily available, inexpensive, easy-to-work modelling materials. Material: The tooling prepreg which August Krempel Soehne GmbH + Co. uses for building its tools is based on a multi-...

Kunststoffe international, 2005-11-21, High Throughput and Flexible Systems
...ystems only the surface is depleted of volatile components. Practically no transport comes from deeper layers. The surface material must be mixed extremely well into the melt pool again. Only in this way can an even reduction of the concentration be achieved. Often degassing from thin layers is discussed. This is clearly less effective than degassing from a constantly renewed surface. Systems such as the co-kneader [11] or other "thick layer" systems are therefore also suitable for degas...

Kunststoffe international, 2005-11-21, High-efficiency Polymeric Foam: Improving Occupant Safety
...motion headform in FMVSS201u or the instrumented pendulum in ECE R21-FMVSS201) is moving at constant velocity before impact [3]. FMVSS201u tests at component level showed that high-efficiency EA countermeasures enable optimum energy management to be achieved in terms of injury levels, while minimising weight and space utilisation (Fig.2) [4]. The advantages offered by high-efficiency EA countermeasures make them ideal for fixing critical situations that arise shortly before the start of producti...

Kunststoffe international, 2005-11-21, High-output Compounding
...etter the filling of the screw channel in the feed section, the higher the output per screw revolution. Specific output therefore depends on the degree of channel filling and the bulk density of the feedstock in the screw channel. To achieve the best possible filling of the screw channel, a bulk product with good free-flowing properties is required. Crammers compact the bulk product at the expense of flowability and this places a limit on the maximum possible compaction. In terms of specific out...

Kunststoffe international, 2005-11-21, High-performance Elastomers: From Abrasion Resistant to Self-healing
...ilisation, e.g., they can replace coatings under the bonnet because they undergo less yellowing. Multilayer protective and decorative film is frequently coextruded, including with different PA 12 moulding compounds (all Vestamid grades), to achieve the optimum balance of surface protection, decorative effect and bondability with sub-constructions. Versatile and Special in Applications All PA 12 elastomers can be welded to each other and to PA 12 (grade: Vestamid L). This applies especially to ...

Kunststoffe international, 2005-11-21, High-performance Machines for Short Cycle Times: New "High-Speed" for Thin-Wall Part
... ensures that the sequence of movements is optimised independently of the opening stroke. Second, at the end of the closing movement, the transmission ratio increases sharply; at constant crosshead speed, the platen speed decreases dramatically. To achieve locking of the toggle, the crosshead must traverse a comparatively long distance, which costs time. To save on this time, especially during the closing movement, the toggle crosshead does not run as far as the locking position. Rather, some of...

Kunststoffe international, 2005-11-21, High-perspective Location
High-perspective Location BASF Schwarzheide Attracts Investors Through investments of around DM 2 billion, BASF Schwarzheide GmbH has gradually become a highly competitive site within the BASF Group. The company is aiming to achieve a turnover of DM 1 billion in the coming year. Through attractive investment promotion schemes, it is hoped that in particular plastic converters will re-locate to the site during the next few years. The Schwarzheide site in the southern part of the German Sta...