J-Soft - SEBS - Newport Elastomers

Plastics Technology, 2004-03-24, How to Optimize Adhesion in Hard-Soft Overmolding
Preventing dissimilar layers from peeling, curling, or separating is critical in overmolding. The challenge has increased along with the variety of materials used. Follow these tips to minimize hard-s...

Plastics Technology, 2004-03-31, Lightweight TP Composite Takes the Driver"s Seat
A lightweight version of Azdel glass-reinforced polypropylene sheet is gaining ground in a host of new automotive applications. Already established in interior headliners, parcel shelves, and sun shad...

Plastics Technology, 2005-03-04, Unusual TPOs Displace Other Plastics In Hard and Soft Auto Parts
The advance of TPOs into new interior and exterior automotive applications was the theme of the latest annual Automotive TPO Global Conference, sponsored by the Society of Plastics Engineers in Dearbo...

Plastics Technology, 2005-07-06, TPUs Get Softer, Slicker, Lighter
BASF Corp., Wyandotte, Mich., has launched a new range of thermoplastic polyurethanes that push the performance envelope in several directions. The company has broken new ground with a non-plasticized...

Plastics Technology, 2008-03-04, New Material Cures LSR Molding Headaches
For some problems the solution is to be soft but also be strong. That was certainly the case for one injection molder of liquid silicone rubber (LSR) and its customer, a producer of earplugs for swimm...

Plastics Technology, 2008-10-23, TPEs Move Up the Performance Scale
This first of two articles on directions in TPE development focuses on styrenic, copolyester, polyamide, and TP urethane elastomers. The following article (p. 64) covers olefinics-- TPOs, TPVs, and PO...

Plastics Technology, 2010-03-08, Do"s and Don"ts for Overmolding Liquid Silicone onto Thermoplastics
Hard/soft overmolding has become a fundamental technique for injection molders in recent years, and a growing number of molders are extending that technology thermoset/thermoplastic combinations. In s...

Plastics Technology, 2010-06-01, Getting Started in LSR: Understanding the Materials
Liquid silicone rubber (LSR) injection molding is a long established process but it is enjoying an upsurge in interest for medical, automotive, infant care, and general industrial applications. LSR is...

Kunststoffe international, Almost like Human Bone
One awkward movement during football training and a cruciate ligament can be torn. The traditional treatment for such injuries, involving the use of metal implants, has a number of disadvantages, especially for the patient. To support an improved process for patient healing, Evonik has developed three bioresorbable polymer composites with ceramic additives that simulate the human bone. For more than 30 years, bioresorbable polymers have been used in orthopedic surgery for medical devices such as...

Kunststoffe international, Foam Beads in Gliding Flight
The particle foam crowd cannot complain about a lack of interest by potential users. At least as far as demand for products with high-quality functional and optical surfaces is concerned. However, development has stagnated since the joint research project SamPa sponsored by the German Federal Ministry of Education and ‧Research reached its conclusion. There is an urgent need for action. One year after the status report “Schaumperlen im Aufwind” (Kunst‧stoffe 2/2019, pp. 21–28, only available in ...

Kunststoffe international, From the Roll to the Third Dimension
The company Leonhard Kurz is a specialist in the development and production of decorative and functional coatings for plastics applications, which are applied by means of carrier foils during injection molding. Essential objectives of the company are technology and process development as well as the optimization of the 3D foil forming around corners and the contours of the plastic parts. For this purpose, Kurz operates an extensive injection molding technology center. New in the machinery: two p...

Kunststoffe international, Medical Applications of Additive ‧Manufacturing
Anyone who introduced additive manufacturing (AM) in a company 15 years ago was a visionary. Anyone who did not do so ten years ago fell behind the early adopters. Anyone who still is not using additive manufacturing today is losing their edge over the competition. What this technology is considered capable of today and how it can be applied in many areas of application is shown (representative) by this expert’s view of medical technology. Additive manufacturing (AM) is bringing about increasing...

Kunststoffe international, Polymer Materials
Polymer materials, including synthetic polymers, have a bad reputation. These image problems do not just arise from the current environmental debate but also have earlier origins. In the past, too, polymer materials were subject to unjustified criticism. This often stemmed from non-scientists and frequently betrayed a lack of scientific knowledge. Plastics have a massive image problem. They are often seen as a symbol of environmental pollution. In addition, they are still considered by many cons...

Kunststoffe international, Rattle-Free Part
At the US location in Auborn Hills, Michigan, fischer automotive systems produces kinematic components for the center console of the Mercedes GLE class, which are equipped with a roller blind. The individual slats of the roller blind are manufactured on a large two-component injection molding machine and, while they are still in the turnkey system, are combined with externally supplied parts to form the finished roller blind. It takes almost a bird’s eye view to get an overview of the size and c...

Kunststoffe international, Sustainable Growth
The central issue in all polyurethane applications is the conversion from the past linear economy into a ‧circular economy, and the use of sustainable raw materials in manufacturing. To do so, manufacturers are ‧taking measures such as using bio-based raw materials, chemical recycling, and CO2 as a synthesis component. Digitalization, electromobility, autonomous driving and the construction industry are also driving PU development. In 2019, global demand for polyurethane (PU) saw a significant b...

Kunststoffe international, 2005-11-21, Above Average Growth of TPE
Above Average Growth of TPE Strategic Market Study Points to Potentials Eckhard Schäfer, Heidelberg/Germany The market for thermoplastic elastomers is growing annually at two decimal rates. While for some types of TPE this growth is exceptional, a number of other materials are being replaced by TPE. An extensive market study by the Lean Management Zentrum, Heidelberg, shows future trends. In the next years sales of thermoplastic elastomers (TPE) will grow by 8 to 36 % annually depending ...

Kunststoffe international, 2005-11-21, Additives: Custom-engineered Plastics
Custom-engineered Plastics Additives. Whether flow behaviour, colour or hardness – the properties that characterise a plastic are determined by additives that become more application-specific every year. Small amount, large effect – the action of additives can be summarised with these words. For years, manufacturers have striven for continuous improvement of their products, matching flame retardants, pigments and stabilisers more and more exactly to the requirements of customers and the market. ...

Kunststoffe international, 2005-11-21, Additives: Tough and Heat-resistant: New Silicone Particles for Thermosets
Thermoplastic Elastomers Tough and Heat-resistant: New Silicone Particles for Thermosets Additives A new generation of nanoscale silicone and core-shell particles is revolutionising the modification of heat-resistant thermosets. Even small additions of the new particles significantly increase the impact strength and fracture toughness of reactive resins and other plastics. Jochen Ebenhoch Highly crosslinking reactive resins, such as hot-curing epoxy resins, bismaleimide resins or cyanate resins ...

Kunststoffe international, 2005-11-21, Air Ducts under the Bonnet
Air Ducts under the Bonnet Flexible Polyamide 6 - a Good Alternative for Flexible Blow Mouldings Ralph Kettl, Domat/Ems, Switzerland With flexible polyamide (PA 6), processing problems in sequential coextrusion of hard-soft combinations are consigned to the past. Air ducts in the engine compartment, for example, can be produced more cost-effectively than before with this material. In addition, a new bellows concept permits replacement of rubber parts by plastic. Easy processing and cost ...

Kunststoffe international, 2005-11-21, An Overview: Innovative Processing Techniques
An Overview: Innovative Processing Techniques In addition to classic production techniques, alternative techniques for processing engineering plastics are becoming established in the automotive industry, often bringing substantial product improvements and savings. Particularly promising examples are outsert moulding, two-component injection moulding, microfoaming and laser welding. Ulrich Haack To be able to survive at an international level, auto makers and their highly specialized suppli...

Kunststoffe international, 2005-11-21, Attractive New World of Packaging
Attractive New World of Packaging Husky Builds on its Strengths in the PET Market PET bottles are the fastest growing market in the packaging segment. Husky, a major globally operating manufacturer of injection moulding machines and tools for the production of preforms for PET containers, is intent on participating in this growth. A report from the company’s European headquarters in Dudelange/Luxembourg. Reliable forecasts for the coming decade predict an annual growth for PET bottles of o...

Kunststoffe international, 2005-11-21, Automotive Safety Parts: Sophisticated Occupant Protection
Injection Moulding Sophisticated Occupant Protection Automotive Safety Parts. In the interior design of modern cars, safety aspects play just as big a role as a high-quality appearance of the plastic components used. Gentner GmbH, Barthelmesaurach/Germany, has specialised in the production of safety-critical injection mouldings for the automotive industry, in particular in the airbag region. Robert Burzler Founded in the mid-60s by Walter and Paula Gentner, the company was initially a contract...

Kunststoffe international, 2005-11-21, Back-compression Moulding: Instrument Panel with Integrated Airbag Flap
Back-compression Moulding: Instrument Panel with Integrated Airbag Flap In the space of only 18 months, Peguform und Kaufmann succeeded in developing an instrument panel for the Chrysler Crossfire to production maturity using a new injection-compression moulding process. The foam-backed TPO coverstock used for the part gives a high-quality surface with a soft touch. The development and validation of the integrated passenger airbag took six months. Ali Hassanzadeh, Hans Schirmer, Georg Kaufma...

Kunststoffe international, 2005-11-21, Bank Rating: Leadership – An Important Rating Factor
Market Leadership – An Important Rating Factor Henry Weber Bank Rating. The performance and commitment of the workforce depend very much on the method of leadership. Staff motivation and staff skills affect the corporate result and thus count as "hard" success factors. Another assessment criterion for the bank rating is the style of leadership, which will affect the future financing of the company's activities. To be in a better position to appraise loan default risks, companies a...

Kunststoffe international, 2005-11-21, Beer Bottles - A New Market for Polyester
Beer Bottles - A New Market for Polyester Brigitta Otto and Michael Streng, Frankfurt/Germany The market for PET for packaging is set to grow to approximately 11.4 million t by the year 2008. It is predicted that some 427,000 t/year will go on the production of beer bottles. Beverages in PET bottles (PET = polyethylene terephthalate) are booming. An increasing number of drinks producers are opting for the lightweight and unbreakable alternative to the heavy glass bottle, not only in the ca...

Kunststoffe international, 2005-11-21, Coinjection of Thermoplastics and Elastomers
Coinjection of Thermoplastics and Elastomers Technical and Economic Aspects of a New Coinjection Technology Christoph Lange and Thomas Hungerkamp, Munich/Germany The production of composites by coinjection moulding is state of the art. High-precision, modular injection moulding machines and innovative mould technology now allow crosslinking elastomers to be injected in combination with thermoplastics. The economic efficiency of these new polymer/elastomer composites depends critically on...

Kunststoffe international, 2005-11-21, Colour Variation: Two Components, Four Colours, Five Units
Injection Moulding Two Components, Four Colours, Five Units Colour Variation. A five-component injection moulding machine with an 8-cavity 3-station rotary mould can produce, in a single process, four different coloured toothbrush mouldings with a soft-touch surface, each from two components. The 350 injection unit for the basic toothbrush bodies is horizontally arranged on this machine, and the four 100 injection units for the coloured soft-touch surface are aligned vertically. Christoph Sch...

Kunststoffe international, 2005-11-21, Colours in Light
Colours in Light Aliphatic TPU for Lightfast Car Parts Jürgen Hättig, Wolfgang Drube, Leverkusen/Germany, and Wolfgang Kaufhold, Dormagen/Germany A new thermoplastic polyurethane elastomer (TPU) based on aliphatic isocyanates is more lightfast than conventional aromatic TPUs and allows the production of light-coloured parts. It opens up possibilities for high-quality, aesthetic automotive design. Thermoplastic polyurethane (TPU) has been used in automotive engineering for many years for ...

Kunststoffe international, 2005-11-21, Combined Process: Foamed Parts with Excellent Surface Quality
Combined Process: Foamed Parts with Excellent Surface Quality The aim of applications engineering must be to combine two special processes in such a way that the combined process can be technically mastered under practical conditions, that the advantages of both processes are exploited and that the user, in an ideal case, gains an added benefit. An impressive example is the combination of Monosandwich and MuCell processes. Jörg Dassow In injection moulding, many special processes often com...

Kunststoffe international, 2005-11-21, Complete Automation: Articulated-arm Robots for Difficult Assembly Operations
Automation Articulated-arm Robots for Difficult Assembly Operations Complete Automation. The production of very small components for high-quality electric shavers and writing implements requires great care and accuracy. Articulated-arm robots are excellent for such requirements, as is shown by three-shift production at Wehrle. In the robot cells, high-speed 16kg six-axis robots from Reis Robotics with sophisticated gripper technology perform the handling and assembly of the precision parts. Fran...

Kunststoffe international, 2005-11-21, Compostable Material: Thermoformed Packaging Made of PLA
Compostable Material: Thermoformed Packaging Made of PLA Polylactides (PLA) represent a new group of thermoplastics for packaging applications obtained from renewable resources. In extensive tests, the functional and thermoforming properties of PLA were compared with those of other polymers. Luc Bosiers, Sven Engelmann Polylactides (PLA) represent a new group of thermoplastics for packaging applications obtained from renewable resources. PLA’s properties make it suitable for various thermo...

Kunststoffe international, 2005-11-21, Comprehensive Product Range: Advancing into New Dimensions
Thermoforming Advancing into New Dimensions Comprehensive Product Range. A Danish processor has turned the advantages offered by thermoforming into a comprehensive and versatile product range. Now the addition of a new thermoforming machine to the processor's machinery line-up is opening up the possibility of new part dimensions. Bernhard Rost Gibo-Plast of Skjern/Denmark employs modern production methods to manufacture sophisticated parts in different colours and textures. Individual ideas...

Kunststoffe international, 2005-11-21, Continued Strong Growth: PET in Beverage Packaging
Trend Report: Engineering Plastics PET in Beverage Packaging Continued Strong Growth. The raw material of PET has undergone a change. Modified product grades now permit even faster injection moulding cycles and higher cycling rates in bottle production. In addition, the grade of PET (in combination with different barrier materials) and the bottle design have been aligned to the bottled product. Kajetan Müller Frank Welle Polyethylene terephthalate (PET) is continuing to show high growth in th...

Kunststoffe international, 2005-11-21, Cost-effectiveness: In-mould Decoration on Modified Standard Machines
Cost-effectiveness: In-mould Decoration on Modified Standard Machines Back-moulded surfaces for car interiors in the compact class are becoming more and more sophisticated in their design. Although such car series are produced in large quantities, there is little margin for error on costs. When certain modifications are made to standard injection-moulding machines, these can also fulfil the technical and economic requirements for back-moulding decorative surfaces. Ante Vasilj, Martin Schmidt...

Kunststoffe international, 2005-11-21, Customised Mould Technology: Integrated Rotary Platform for Flexible Two-Component Production
Automotive Tooling Integrated Rotary Platform for Flexible Two-Component Production Customised Mould Technology. For a new car central console, a two-component mould has been developed in which the rotary platform is integrated into the mould direct rather than in the clamping platen. This gives processors the flexibility to use the mould in combination with a side injection moulding unit on different machines. Uwe Steinmeyer Otto Kunststoffverarbeitung Crock GmbH specialises in the productio...

Kunststoffe international, 2005-11-21, Cutting Costs, Increasing Benefits: Multi-Component Injection Moulding as Innovation Driver
Cutting Costs, Increasing Benefits: Multi-Component Injection Moulding as Innovation Driver For products to remain viable, they must offer added functionality and design combined with lower production costs – a condition that can only be met with innovative production processes.In this article, Wilden AG in Regensburg/Germany, uses a series of sample products to demonstrate the development potential that can be unlocked by multi-component injection moulding. Herbert Argauer, Andreas Eder, Ka...

Kunststoffe international, 2005-11-21, Dashboards Meet Highest Requirements
Dashboards Meet Highest Requirements New Market for Slush-moulded Skins Made from TPU Jürgen Hättig, Leverkusen/Germany, and Wolfgang Kaufhold, Dormagen/Germany The requirement profile for dashboards can be roughly divided into the categories of safety, appearance, touch and environmental friendliness. Because of increased requirements, particularly in relation to airbag technology, the use of moulded skins based on thermoplastic polyurethane (TPU) is growing in importance. A car dashboa...

Kunststoffe international, 2005-11-21, Decoration on the Front, Attachments on the Rear
Decoration on the Front, Attachments on the Rear Producing the Interior Trim of an Automotive Door by Integrated Decoration Compression Moulding Richard Hahnekamp, Munich/Germany, and Georg Kaufmann, Busslingen/Switzerland The very finest in mould technology, production techniques and logistics all go into the production of the different versions of the interior door trim for the convertible and coupé of the 3-series BMW by integrated decoration compression moulding. This article describes...

Kunststoffe international, 2005-11-21, Development Trends: Extrusion Blow-moulded Automotive Components
Development Trends: Extrusion Blow-moulded Automotive Components Extrusion blow moulding of industrial automotive components is currently undergoing dramatic changes which affect both suppliers and products alike. Suppliers of blown components have to struggle with an increasing cost pressure – product innovations and efficient technologies for a better production efficiency are called for now. Axel Birk More than ever before, suppliers to the automotive industry are compelled to deliver h...

Kunststoffe international, 2005-11-21, Dimensioning Parts: Non-linear Viscoelasticity
Simulation Non-linear Viscoelasticity Ernst Schmachtenberg Marcel Brandt Dimensioning Parts. Precise description of the non-linear viscoelastic material behaviour of thermoplastics in FEA makes it possible to exploit the mechanical potential of these materials in the best way possible and to optimise the development of corresponding parts. As more and more plastics are used in technical applications, design reliability and parts dimensioning are coming increasingly into focus. Shorter devel...

Kunststoffe international, 2005-11-21, Easy-opening Concepts: Easy-opening Sterile Packaging
Easy-opening Concepts: Easy-opening Sterile Packaging Packaging for medical devices, operating-theatre apparel, wound dressings and sterile sheets for medical applications needs to be easy and quick to open. No particles or fibres are allowed to become detached from the torn surface, however. Traditional peel concepts already satisfy this requirement, but a new innovative material combination with a spunflash nonwoven is able to offer further benefits. Heiko E. Schenck, Malik Zeniti In Nor...

Kunststoffe international, 2005-11-21, Elastomers: Flexible and Customised
Trade Fair Report Flexible and Customised Elastomers. Thermoplastic elastomers (TPE) are now indispensable for applications ranging from everyday items to underhood components. On the "rubber line", trade visitors were able to assess the merits of special developments in synthetic rubbers, which account for by far the largest proportion of elastomers. The automotive industry remains an essential driving force for the market. After years of strong growth, thermoplastic elastomers – a grou...

Kunststoffe international, 2005-11-21, Electrically Conducting Compounds: New Functional Material for the Automotive Sector
Automotive - Functional Materials New Functional Material for the Automotive Sector Electrically Conducting Compounds. Electrically conducting components used in the automotive sector, are generally made in complicated multi-stage processes. An alternative is offered by a new material in which a low-melting alloy is incorporated along with copper fibres into a thermoplastic matrix. Electrically and thermally conducting components are becoming more important in the automotive sector. Electrica...

Kunststoffe international, 2005-11-21, Exactly Suited Material Preparation: Reliable Use of PET Flakes
Recycling Reliable Use of PET Flakes Exactly Suited Material Preparation. Economic supply of PET ground stock from beverage bottles offers an attractive potential for lowering manufacturing costs. Drying and crystallisation plants should not be regarded as unnecessary evils, but as important process units for qualitatively high-value production. Michael Zlotos PET finds application in many production processes, be it in the field of packaging for bottle production or production of packaging foil...

Kunststoffe international, 2005-11-21, Exhibition Preview: North American and Canadian Products at K 2004
USA-Special North American and Canadian Products at K 2004 Exhibition Preview. In Düsseldorf, more than 140 U.S. American and Canadian Companies will present their innovations for the first time to an European specialist audience. The editors of the magazine Plastics Technology have assembled a selection of the most important developments. With this thematically structured preliminary report you can effectively prepare your visit at the K show. Injection Moulding News from includes all-electr...

Kunststoffe international, 2005-11-21, Fewer Production Stages, Shorter Cycles
Fewer Production Stages, Shorter Cycles Decorated Large Moulded Parts Made by the One-Shot Process Carsten Brockmann, Bötzingen/Germany Jochen Mitzler, Munich/Germany The one-shot process is the latest buzz phrase in decorative plastics processing. Its goal is to produce decorated moulded parts in a genuine one-shot process on horizontal injection moulding machines - without the laborious processing stages that have previously been needed by the laminating adhesive method. The steadily g...

Kunststoffe international, 2005-11-21, Flame Retardants: Growing Demand
Additives Growing Demand Flame Retardants. Increasing internationalisation and more stringent fire-protection requirements are opening up promising markets for flame retardants and flame-retardant plastics. Halogen-free products will benefit in the electrical sector thanks to the forthcoming introduction of the EC Directive on Waste Electrical and Electronic Equipment. The trade fair K2004 served as an indicator of the general growth in demand for plastics and the increasing use of flame-reta...

Kunststoffe international, 2005-11-21, From Operating Point to Operating Window
From Operating Point to Operating Window Variable-speed Drive for Large Twin-screw Extruders Werner Kreutzer and Bernhard Stöhrer, Stuttgart/Germany For the first time an override gear for large extruders in polymerisation plants makes it possible to combine an economical fixed-speed main motor with a smaller less expensive variable-speed secondary motor. This results in a variable-speed extrusion drive that until now has not been available at this price performance ratio. For economic r...

Kunststoffe international, 2005-11-21, Functional Compounds
Functional Compounds Properties and Applications of Magnetite/Plastic Compounds Peter Duifhuis, Rotterdam, Bernd Weidenfeller and Gerhard Ziegmann, Clausthal-Zellerfeld/Germany The mineral, magnetite, is of key importance for the iron and steel industry. Its role as a functional filler for plastics, however, is relatively new. Thanks to its outstanding properties, this filler has already gained ground in many applications, right through to the automotive industry. The increasing use of p...

Kunststoffe international, 2005-11-21, Gas Phase Fluorination: Reducing Plasticiser Migration
Additives Reducing Plasticiser Migration Gas Phase Fluorination. Plasticisers have special importance in producing PVC. They can be used to adjust the properties of PVC over a wide range from hard to leathery soft. The plasticiser migrates from the PVC and accumulates on the surface. Plasticiser migration from PVC can be significantly reduced by pretreatment with gas phase fluorination. Sindy Mosch Carsten Rehwinkel Bernd Möller Since the beginning of mass production in the last century plastics...

Kunststoffe international, 2005-11-21, Gear Lever in Hand
Gear Lever in Hand Two Component Concept for Private Cars Petra Schroeder and Thomas Ruff, Bad Urach/Germany, Armin Dworschak and Bernard Rzepka, Kerpen/Germany Early co-operation of materials, manufacturing and design experts has led to development of a new concept for passenger car gear lever knobs. It is characterised by use of the materials combination PP/SEBS that makes economic production in the 2-component injection moulding process possible. Until now high-quality passenger car g...

Kunststoffe international, 2005-11-21, General-purpose Plastics: Appearance Ever More Important
Trade Fair Report Appearance Ever More Important General-purpose Plastics. Aesthetics could well have been the motto for general-purpose plastics at K 2004. Whether it is a matter of greater transparency and surface gloss for more attractive packaging or flawlessness and improved scratch resistance for automotive parts – appearance would seem to be assuming ever greater importance at present. Alongside this, progress in mechanical and processing properties has not been forgotten either. The p...

Kunststoffe international, 2005-11-21, GIT, Sandwich and Two-component Moulding in Practice and Research: Correct Application of Multicomponent Processes
25 Years of KTP Correct Application of Multicomponent Processes GIT, Sandwich and Two-component Moulding in Practice and Research. The article gives a brief survey of gas-assisted injection moulding, multi-component composite injection moulding and sandwich injection moulding. It highlights application problems in practice and potential solutions from research at the KTP. Despite the fact that the term "multicomponent process" is only used in the literature in the context of the injectio...

Kunststoffe international, 2005-11-21, Growth through Specialities: New Markets and Individual Compounds
Distribution and Compounding New Markets and Individual Compounds Growth through Specialities. The distributor and compounder, Albis Plastic, plans further growth by adding complementary products and specialities to its core product range. Albis in-house developments are also important focal points for cooperation with OEMs. The Germany company Albis Plastic GmbH, Hamburg, is systematically pursuing its strategy of adding complementary products and specialities to the core product range it han...

Kunststoffe international, 2005-11-21, Guest Editorial: “Constant Innovation is a Key Requirement”
Guest Editorial “Constant Innovation is a Key Requirement” With a share of roughly one-third, Europe will remain a major contributor to global production of plastics into 2010 and beyond. Dr. Günter Hilken, head of the Business Unit Polycarbonates at Bayer MaterialScience and chairman of PlasticsEurope Deutschland, commentates on the current situation and the forecasts for growth in the plastics industry. Dr. Günter Hilken on the future of plastics production in Germany, Europe and the world ...

Kunststoffe international, 2005-11-21, Handling: Tightly Packed
Injection Moulding Tightly Packed Handling. Helvoet B.V. has been involved in processing rubber and plastics for over 60 years. The company made its name as a manufacturer of high-precision technical components in the micro and small parts sector. The article presents a system for producing two-component adapters with high-precision parts placement. The Netherlands-based processor Helvoet B.V. manufactures parts and components using a wide variety of technologies. They include semi- and fully au...

Kunststoffe international, 2005-11-21, Hard-soft Composites with Metal Inserts: New Generation of Plastic-Metal Hybrids
Automotive New Generation of Plastic-Metal Hybrids Hard-soft Composites with Metal Inserts. Technical and functional advantages can be generated by using a combination of different materials. Metal-hybrid parts consist of metal support structures over-moulded with functional plastic elements. A damping inter-layer to reduce loading and warpage can be introduced between the metal and plastic by means of MCDS (multi-component damping system) technology. Gottfried Steiner Ralf Gerndorf The charac...

Kunststoffe international, 2005-11-21, Heavier, Wider, Higher
Heavier, Wider, Higher Packaging of Foam Rolls It is not an easy task to reliably package foam rolls weighing up to 350 kg with diameters up to 2400 mm. The foam manufacturer Otto Bock of Duderstadt/Germany has gained good experience with a new packaging line. The Otto Bock Group has its roots in health-care technology. With the foundation of spin offs in the field of plastics technology and information and communication technology, the company has developed into a middle-sized, diversifie...

Kunststoffe international, 2005-11-21, High Requirements - Low Investment Costs
High Requirements - Low Investment Costs LFI-PU Process: Ripe Flexible Technology Wolfgang Frehsdorf and Wolfgang Söchtig, Munich/Germany The trend toward light construction in automobile manufacture continues unbroken. More and more frequently plastics provide light-weight solutions where metals have been used for decades. The LFI-PU-process, for which no pre-formed glass mats are necessary, was developed for making large, complex parts. Instead, a mixing head supplies the moulds with a P...

Kunststoffe international, 2005-11-21, High-Grade Film Production
High-Grade Film Production Special Film Properties through Sleeve-Touch Surface Polishing Jürgen Miethlinger, Lenzing/Austria The new Sleeve-Touch technology can be used to produce highly transparent film which is glossy on both sizes, suffers minimum shrinkage and displays good flatness. The process involves two-sided surface polishing and cooling of the melt web. The development and improvement targets being pursued for extrusion plants are characterised especially by the following mea...

Kunststoffe international, 2005-11-21, High-performance Elastomers: From Abrasion Resistant to Self-healing
High-performance Elastomers: From Abrasion Resistant to Self-healing Polyamide 12 elastomers stand out from competing thermoplastic moulding compounds thanks to a wide range of high-quality elastic properties. They are therefore used both for demanding precision injection-moulding parts and for select extrusion applications in the sports equipment and automotive sectors. Michael Beyer, Ursula Keil Higher, faster, more beautiful, better – not even materials development is immune to the hunt...

Kunststoffe international, 2005-11-21, Injection Moulding Trends: Increased Complexity and Tighter Specifications
Injection Moulding Trends: Increased Complexity and Tighter Specifications Automation, substitution, specialisation, rationalisation: this is how the author sees plastics processing in the future. Herbert Kraibühler Plastics processing is assuming ever-greater significance on the market. A key role is being played here by new developments in the fields of - drive technology, - automation solutions, - the substitution of traditional materials and production processes by plastics and inje...

Kunststoffe international, 2005-11-21, Innovation through New Processes
Innovation through New Processes Walter Michaeli and Edmund Haberstroh, Aachen/Germany Many technical developments in the automotive industry, aeronautical engineering and the electrical and communications sectors would be inconceivable without the specifically tailored application of polymeric materials. Material and process development have to go hand in hand here to achieve the required advances. This gives rise to a constant demand for new or modified processing and simulation technologi...

Kunststoffe international, 2005-11-21, Innovations Today and Tomorrow: Polypropylene for Flexible Packaging
Packaging Polypropylene for Flexible Packaging Innovations Today and Tomorrow. The continuous improvement of flexible plastic packaging – driven primarily by the wishes of the consumer – is being helped along by the constant further development of polypropylene. With both flexible and rigid films – and especially with transparent cast film – enormous progress has been made in the last ten years. An important new impetus has also been provided by the development of new easy-to-open, easy-to-han...

Kunststoffe international, 2005-11-21, Innovative Design Opportunities for Magnet Technology: Injection Moulded Permanent Magnets Employing the Two-component Technique
Innovative Design Opportunities for Magnet Technology: Injection Moulded Permanent Magnets Employing the Two-component Technique A plastics processor has developed a process that can be used to produce injection-moulded, permanent magnets with improved magnetic and mechanical properties. Michael Stadler, Wolfgang Koos Plastic-bonded magnetic materials with fillers such as SrFe, BaFe, NdFeB and SmCo are used first and foremost on account of the freedom of design that the injection moulding ...

Kunststoffe international, 2005-11-21, Inserting, Foaming and Coating
Inserting, Foaming and Coating Handling of Particle-Foam Parts Klaus Baumann, Hasloch/Germany In the production of EPS moulded parts, handling problems cannot always be solved by standard removal systems. It is sometimes necessary to add on a standardised universal handling system so as to be able to cover speciality applications. The examples presented below illustrate different solutions used in practice. Moulded parts are mostly produced where they are not needed. Totally irrespective...

Kunststoffe international, 2005-11-21, Integrative Processing Technology: Injection Moulding Processes – Yesterday, Today and Tomorrow
Special Injection Moulding Processes – Yesterday, Today and Tomorrow Integrative Processing Technology. As one of the most important processing technologies, injection moulding has experienced, by far, some of the greatest advances in recent decades. From its origins based on simple moulding of thermoplastic resins, a product-specific processing technology has been developed that has as its objective production of complex parts via a combination of various individual processing techniques. Erw...

Kunststoffe international, 2005-11-21, Interview: "Success Through Global Technological Expertise"
Interview The circle closes – even if in a round-about way: The then Balda GmbH sold its camera production to China in 1985, bidding good-bye to this division. Balda is now a stock market-listed company split into three business groups: Infocom, Automotive and Medical. Through the field of mobile telephony, it has made a return to cameras in the form of camera phones. Clemens Doriat, one of the editors of Kunststoffe, met Ralf Ackermann, the member of the Board of Management of Balda responsible...

Kunststoffe international, 2005-11-21, Interview: Quo Vadis Polycarbonate Glazing?
Interview Polycarbonate (PC) has made the breakthrough into automotive glazing. This was the view of experts from Bayer MaterialScience AG at a company press conference. But where is the technology headed, and what are the challenges that it has to face? Quo Vadis Polycarbonate Glazing? Volkhard Krause, head of the Automotive Glazing Team at Bayer MaterialScience, talks about the current state of affairs and future developments. ? For a long time, wear-resistance and weatherability were consi...

Kunststoffe international, 2005-11-21, Laser Welding A Mature Joining Technique
Laser Welding A Mature Joining Technique Practical Uses Christian Bonten, Ernst Schmachtenberg and Carsten Tüchert, Essen/Germany Laser welding technology is developing at a ferocious pace, especially laser transmission welding. Numerous examples have borne out the practical implementation and application of this recent, yet mature, laser welding technology. The advantages of joining engineering plastic parts by means of laser welding are vibration-free, non-contact warming of the joint ...

Kunststoffe international, 2005-11-21, Low Manufacturing Costs: Plastics Encapsulation for Solar Modules
Photovoltaics Plastics Encapsulation for Solar Modules Low Manufacturing Costs. Solar modules can be more economically manufactured using a variety of plastics than with traditional materials, and at the same time additional functions can be integrated into the module. Plastic encapsulants will therefore reduce the manufacturing costs for solar modules in future. Almost all modern solar modules have an identical construction (a glass-EVA-PVF-laminate; PVF = polyvinyl fluoride, trade name Ted...

Kunststoffe international, 2005-11-21, Machine Control: Better Quality and Productivity
Blow Moulding Better Quality and Productivity Machine Control. For consistently high product quality in blow moulding, it is necessary that the most essential production steps be controlled via closed loop instead of open-loop control. This method results in high reproducibility, consistent quality, process acceleration and, in turn, enhanced productivity. Harald Kronemeyer The last generation of the TMC-4 machine control produced by the Moog GmbH, Böblingen, is designed for all types of bl...

Kunststoffe international, 2005-11-21, Market Report (2): A Year to Forget
Market Report (2): A Year to Forget Consumption of plastics in Italy in 2002 was considerably lower than in previous years, with virgin material growing by just 1.4%. Growth in the use of recycled materials was hampered by a shortage of recyclable materials in the first few months and then by a decline in the prices of the raw materials later in the year. These are the conclusions reached in a market study conducted by Plastic Consult. The economic situation in Italy continued to deteriorate...

Kunststoffe international, 2005-11-21, Marking Plastic Products
Marking Plastic Products Which Technology for which Application? Plastic products can be marked by different methods. The important criteria to be used in selecting the most suitable technology can be determined by comparing the different methods. Patric Lamprecht, Stuttgart/Germany There are various reasons why a plastic product is marked. In the first place, legislation specifies, for example, that a plastic product should be marked with the exact polymer designation to facilitate recy...

Kunststoffe international, 2005-11-21, Materials and Processes: Electrical Engineering in Transformation
Materials and Processes: Electrical Engineering in Transformation Electrical engineering is in a state of change throughout the world. This results in individual trends in plastics applications and processing technology to meet demands. The wide variety of product groups are highly differentiated. Thilo Simonsohn, Gerold Malin The hierarchical structure of power distribution grids – from power stations, via transformer stations, to the consumers (industries, private homes and street lightin...

Kunststoffe international, 2005-11-21, Microsystems Technology: In-mould Assembly via Microinjection Moulding
Special In-mould Assembly via Microinjection Moulding – An Alternative Joining Process Microsystems Technology. Everyday life is increasingly influenced by microsystems technology of all kinds. Expanding use of polymeric materials in this area presents interesting alternatives not only for manufacturing, but also for joining and connecting of microsystems. Walter Michaeli Dirk Opfermann In addition to the continual advances in miniaturisation, the Nexus study identifies the increasing use of ...

Kunststoffe international, 2005-11-21, Modified Polyphenylene Ether (PPE)
Modified Polyphenylene Ether (PPE) Henk Perree, Bergen op Zoom/Netherlands Blends based on polyphenylene ether (PPE) combine the properties of plastics such as polypropylene, polystyrene and polyamide with the familiar high heat resistance, high dimensional stability and good hydrolysis resistance of PPE. Applications are to be found primarily in the automotive sector. Modified PPE blends are well known for their high heat resistance, high dimensional stability, very low water absorption a...

Kunststoffe international, 2005-11-21, Modular Clamping Force: Why a Mould Maker Needs His Own Injection Moulding Machines
Modular Clamping Force: Why a Mould Maker Needs His Own Injection Moulding Machines Processors nowadays expect their mould makers to take responsibility for the process reliability of a new mould. It is therefore becoming increasingly important for mould manufacturers to test the mould under production conditions on their own injection moulding machine, which should be as general purpose as possible. Jürgen Sauer, Franz Starzer To practise his trade, a competition-hardened mould maker need...

Kunststoffe international, 2005-11-21, More elegance . . .
More elegance . . . . . . with injection moulded door frame finishers Günter Bagusche and Matthias Pfeifer, Morsbach/Germany Plastic door frame finishers gives vehicle designers more freedom of design. With suitably chosen colours and surface properties, door frame finishers can make vehicle interiors look and feel more like "home" and improve acoustic properties. In addition, door frame finishers offers automotive manufacturers promising potential for cost reduction, because it el...

Kunststoffe international, 2005-11-21, Motor Vehicle Interiors
Motor Vehicle Interiors Ideas, Concepts, Materials Johannes Seesing, Odenthal/Germany “The Fascination of Cars” – that was the motto of the 59th International Automobile Exhibition (IAA) held last year in Frankfurt. Aside from the latest range of manufacturers’ vehicles, there were again numerous design studies on display for the vehicles of the future. However, not only were complete cars exhibited, but suppliers also presented interesting interior studies showing trend-setting approaches...

Kunststoffe international, 2005-11-21, Mould Design: Advances in Injection Mould Design
Trade Fair Report Advances in Injection Mould Design Mould Design. The trends apparent at the K-Show can be summarised as: combined and optimised technologies, easy to service, compact moulds, and “Fast-to-Market" product strategies. The results of a worthwhile visit. As the individuals who ultimately convert advances in processing into reality, designers of injection moulds are currently in the process of extracting even further benefits for their customers from the technical ideas of t...

Kunststoffe international, 2005-11-21, Mould Design: Safely Warp-free
Mould Design: Safely Warp-free In the design of a panel for a ski-loading hatch in a top-of-the-range car, mould design was supported and verified by simulation of mould filling and warpage. Thanks to this preliminary work, the product could go into mass production rapidly and with no start up problems. Michael Büdinger, Marco Sundermann, Alexander Reisinger Top-of-the-range vehicles must be fitted out with a luxurious but practical interior. For winter holidays, this includes the facility...

Kunststoffe international, 2005-11-21, Mould-making 2000
Mould-making 2000 Tailor Made - Versatile - Innovative Reinhard Bauer, Schwertberg/Austria Over the past 10 to 15 years, mould-making has seen the transition from the craftsman style to industrial production. Practical examples of six Austrian mould-makers - leaders in their different fields - demonstrate the up to date state of art for mould-making and the performance of innovative injection moulding tools. In the final count, this results in an indication of mould-making's position i...

Kunststoffe international, 2005-11-21, Multi-component Moulds: More Colour and More Functions
Multi-component Moulds: More Colour and More Functions Multi-component injection moulding makes it possible to combine the properties of different plastics or incorporate more than one colour in an individual moulded part and thus produce multi-functional parts in a single operation. The wealth of soft-touch mouldings that have emerged over the past few years have more or less made it essential to come up with innovations in the multi-component technique. Bernhard Rief Initial ideas and pa...

Kunststoffe international, 2005-11-21, Multi-component Processing: Plasma Makes for a Strong Bond
Multi-component Processing: Plasma Makes for a Strong Bond In-line activation of polymer surfaces by plasma treatment directly in the injection mould enables positive-joint composites to be made from polymer combinations that were hitherto unable to adhere to each other, markedly improves adhesion of compatible combinations and can be easily integrated into a process chain. Simon Amesöder, Agnieszka Kopczynska, Gottfried W. Ehrenstein Major growth is still being forecast for multi-componen...

Kunststoffe international, 2005-11-21, Multi-material Technology: Always One Step Ahead Thanks to Active R&D
PE 102817 Automotive - Injection Moulding Always One Step Ahead Thanks to Active R&D Multi-material Technology. Multifunctional concepts for plastic parts have achieved their market success as a result of the variety of materials available and technologically advanced processing equipment. To take advantage of multi-material-technology, emerging technological trends must be recognised. Gottfried Steiner Herbert Brunner Christian Schumi The clear trend towards functionally integrated multicompone...

Kunststoffe international, 2005-11-21, Nanoscale NIR Absorbers: Permanently Mark Highly Transparent Plastics
Additives Permanently Mark Highly Transparent Plastics Nanoscale NIR Absorbers. Laser marking of highly transparent plastics represents a challenge, since commercially available laser additives have an intrinsic colour and cloud the plastic. Newly developed processes utilising nanoscale metal oxides now permit laser marking of transparent plastics without any loss of quality. Wilhelm Wolff Among the processes for marking and identifying plastics, the still young technique of laser marking exh...

Kunststoffe international, 2005-11-21, No Crash Helmets Needed in Cars
No Crash Helmets Needed in Cars Structured Foam Impact Protection Konstantin v. Diest, Peter Cate, Schwalbach, und Niek Bindels, Terneuzen/Netherlands A polypropylene honeycomb profile undergoes controlled deformation under impact loads in the extrusion direction. This foam is an excellent, extremely efficient energy absorber. Initial applications include automotive head-impact protection. A novel polypropylene foam (manufacturer: The Dow Chemical Company, grade: Strandfoam) shows, thank...

Kunststoffe international, 2005-11-21, Only the Application Determines the Prototype
Only the Application Determines the Prototype Which RP Process for Which Product? Christian Bonten and Thomas Seul, Essen/Germany This year's Euromold again demonstrated unbridled demand for prototypes. At the same time, it overwhelmed potential users with the variety of prototypes and RP processes on offer. This article helps product developers decide which prototype is suitable for which application. When a product is being developed, the question often arises as to which rapid pro...

Kunststoffe international, 2005-11-21, Optimisation of Screws with Small L/D Ratio: Custom-made Screws
Injection Moulding Custom-made Screws Optimisation of Screws with Small L/D Ratio. The design of small-diameter screws poses severe challenges for machine manufacturers, since the conveying and melting mechanisms are different from those of larger screws. If these screws also have a small L/D ratio, it is difficult to find a universal geometry. But, by adapting the geometry, the desired result can be found even with short screws. Christian Gornik Harald Bleier Increasing cost pressure on process...

Kunststoffe international, 2005-11-21, Package Solution: Production System for Screw Caps in China
Injection Moulding Production System for Screw Caps in China Package Solution. Injection moulding machine manufacturer, Demag Ergotech GmbH, Schwaig, and mould builder, Schöttli AG, Diessenhofen/Switzerland, are jointly marketing a new production system for screw caps in China. The package solution, consisting of high-speed injection moulding machines and multi-cavity moulds, not only saves material and energy, it also brings shorter cycle times and a fast return on investment. The "Schöt...

Kunststoffe international, 2005-11-21, Partners in the Market
Partners in the Market The Role of Compounders in the Plastics Industry Hans-Jürgen Ott, Gaggenau/Germany There are unlikely to be many fundamentally new polymer classes in the foreseeable future, and compounders therefore have the job of adapting existing polymers to ever more complex applications and requirements. They therefore act as links between polymer manufacturers and plastics processors. A compound is a thermoplastic polymer whose properties have been tailored by the addition o...

Kunststoffe international, 2005-11-21, Parts Handling as a Productivity Factor: Mark-free Gripping of Sensitive Plastic Parts
Automation Mark-free Gripping of Sensitive Plastic Parts Parts Handling as a Productivity Factor. Special suction pads made of special materials reliably remove plastic parts from the mould without leaving marks. This is particularly important when high-quality surfaces are involved, or the parts have to be subsequently painted. Kerstin Löffler The mass production of plastic parts is now largely automated – from material feed to parts removal. To exploit, for example, the maximum number of injec...

Kunststoffe international, 2005-11-21, Peel Testing of Multi-component Mouldings
Peel Testing of Multi-component Mouldings Quantitative Determination of the Bond Strength of Hard/Soft Combinations Werner Aumüller, Tauberzell/Germany Until recently, there has been no practical method for quantitatively measuring the bond strength of hard/soft combinations of thermoplastic elastomers and engineering thermoplastics. Now, with newly developed test specimen geometry and the use of a test method that can determine peel strength, it is possible to measure and compare bond str...

Kunststoffe international, 2005-11-21, PET Boom: PET Recycling and Direct Processing
PET Boom: PET Recycling and Direct Processing Growth in German PET production over the last three years has been above 30 % a year. This is attributable not least to an enormous increase in disposable, non-returnable packaging products made from this material. As a result, technical development has been driven at an above-average rate. Walter Michaeli, Torsten Schmitz Under the aspect of conserving resources, recycling is especially important with high-grade plastic products that have very...

Kunststoffe international, 2005-11-21, PET Bottles Success Story: Polyethylene Terephthalate (PET)
Special: World Market Polyethylene Terephthalate (PET) PET Bottles Success Story. Polyethylene terephthalate (PET) is the plastic that has experienced the biggest growth in demand over the past few years. This development has been prompted by the use of PET as a substitute for glass in bottles for carbonated beverages and mineral water and, increasingly, for beer too. Above-average growth rates are also expected for PET over the years to come. Polyethylene terephthalate (PET) has been used...

Kunststoffe international, 2005-11-21, PET in Packaging
PET in Packaging Prospects and Limitations Horst-Christian Langowski, Frank Welle, Freising/Germany Over the years, no other packaging material has presented the industry with such high growth rates as polyethylene terephthalate (PET). The positive market development is due primarily to the increasing popularity of PET bottles. And the growth is continuing unabated. Now that glass bottles have been substituted to a large extent for mineral water, PET manufacturers and bottle producers ar...

Kunststoffe international, 2005-11-21, Plastic, the All-purpose Material: Function in Form
Plastic, the All-purpose Material: Function in Form The correct plastic for a particular requirement and function can now be found in almost all sport and leisure applications. With its almost unlimited mouldability and colouring, this multitalented material is often used as a substitute for metal, glass or wood products. Gudrun Klein Sport and leisure applications are particularly influential in plastic’s popularity. This is partly due to the commitment shown by the plastics industry as r...

Kunststoffe international, 2005-11-21, Plasticised Thermoplastic Polyurethane: Without Plasticisers
Plasticised Thermoplastic Polyurethane: Without Plasticisers Economic production of rigid-flexible bonds with multi-component injection moulding is increasingly carried out by important OEMs in application ranges such as consumer goods, electrotechnology/electronics and the automobile industry in order to manufacture cost-oriented- innovative products. Also thermoplastic elastomers (TPE) are frequently used as soft components. Andreas Tiemann, Rolf Steinberger Thermoplastic polyurethanes w...

Kunststoffe international, 2005-11-21, Plastics in the Automotive Industry: Symbiosis between Design and Function
Design Symbiosis between Design and Function Plastics in the Automotive Industry. Ever since cars were first built at the beginning of the last century, which was also the time that modern synthetic polymers first saw the light of day, the proportion of these materials in car production has constantly increased. One of the main reasons for this are the modern-day design specifications, many of which can only be met with polymer materials – and in particular, plastics. Plastics combine many uniqu...

Kunststoffe international, 2005-11-21, PMMA - A Substrate for DVD
PMMA - A Substrate for DVD Rudolf Blass and Michael Zietek, Darmstadt/Germany High light transmission, low birefringence and good surface hardness are the qualities that make polymethyl methacrylate (PMMA) a suitable material for the production of DVDs. Besides its use for DVD 5 and DVD 9, which are ready for mass production, it is now being discussed as a candidate for recordable compact discs (CD-Rs). With a capacity of 17 gigabytes, the digital versatile disc (DVD) is capable of storing...

Kunststoffe international, 2005-11-21, Polycarbonate: Flat Screen TVs with Luminescent Aura
Electrical Engineering Flat Screen TVs with Luminescent Aura Polycarbonate. The housing design of the new flat screen plasma TV by Philips with its innovative environmental lighting creates a relaxing atmosphere. Thus, a transparent medium frame made of polycarbonate is integrated between back housing and front cover. The lighting effects are transmitted to the outside via this frame. The new 42" flat screen plasma TV by Philips not only offers razor-sharp images that allow viewers to be ...

Kunststoffe international, 2005-11-21, Polyethylene terephthalate (PET)
Polyethylene terephthalate (PET) Dewey Johnson, Kingsport/USA The polyester and PET market has seen dramatic change over the last 20 years. Polyester fibre is among the most preferred fibres for textile applications with growth in share from cotton, wool, acetate, and synthetic fibres, while PET packaging is today's preferred package for many beverage, food, and household products versus cans or glass. Likewise, equipment and process technologies in polyester, as well as in textiles and ...

Kunststoffe international, 2005-11-21, Polyethylene Terephthalate (PET)
Polyethylene Terephthalate (PET) ... For Packaging Karsten Fritsch, Gersthofen/Germany, and Frank Welle, Freising/Germany In recent years, PET has shown above-average market growth and the forecasts are that it will continue to grow. This is primarily due to the favourable properties of PET packaging, such as break resistance, low weight, transparency, brilliance, mechanical strength and barrier characteristics. The success of PET in the packaging sector is being boosted by the build-up of...

Kunststoffe international, 2005-11-21, Polymer Design and Modification: Polypropylene (PP)
Trend Report: Commodity Plastics Polypropylene (PP) Polymer Design and Modification. With ever-larger production facilities and a decreasing number of producers, polypropylene continues to show its versatility. From catalysts to construction, producers and processors are always working on new solutions with this material, which has made rapid advances since its discovery in 1954 and initial production in 1957. Overall consumption of polypropylene in Western Europe amounted to 7800kt in the ye...

Kunststoffe international, 2005-11-21, Polypropylene (PP)
Polypropylene (PP) Anton Wolfsberger, Markus Gahleitner and Max Wachholder, Linz/Austria Polypropylenes (PP) are the most widely used commodity plastic world-wide. The tremendous market success of these materials results, on the one hand, from their great innovation potential for continuous property expansion and, on the other, from extremely wide application possibilities. This trend is set to continue in future. In 2001, PP consumption in Western Europe reached 6.83m.t. Forty-eight perce...

Kunststoffe international, 2005-11-21, Polyurethane Elastomers
Polyurethane Elastomers Modified Machine Technology for Optimised Material Processing Michael Begemann, Patrick Brüninghaus and Werner Kraft, Sankt Augustin/Germany In the course of extensive reengineering, the processing concept for PU cast elastomers has been improved in all respects. Automated material handling leads to reproducible processes that guarantee consistent material properties. Polyurethane hot casting systems are rubbery-elastic materials. They are produced by pouring a li...

Kunststoffe international, 2005-11-21, Polyurethanes (PUR)
Polyurethanes (PUR) Heimo Lüdke, Leverkusen/Germany, and Stefan Albus, Herne/Germany The subdued economic growth of last year has not left the polyurethane market unscathed. Although the feared collapse never materialised, the industry was characterised by restraint. Technically speaking, too, consolidation was the order of the day. Innovations only occurred in certain important details. Last year, the polyurethane market – like the world economy overall – saw an interruption in its growth...

Kunststoffe international, 2005-11-21, Polyurethanes Every Step of the Way
Polyurethanes Every Step of the Way Polyurethane integral foams are finding increasing use for shoe soles - in ever more applications. Bayer AG recently introduced a new brand concept that will supply shoe manufacturers with targeted information about products and technologies for their particular applications. Statistically, almost two pairs of shoes are produced for every person on earth each year. In 1999, the figure was 11.5 billion shoes overall [1]. As regards the quality of the materi...

Kunststoffe international, 2005-11-21, Possibilities with Plastics: Sports Applications
Sports and Leisure Time Sports Applications Possibilities with Plastics. If we look at sports stadiums, equipment and clothing, we quickly see that almost nothing can be done without plastics. What’s more, without polymers, some sports would hardly be possible at all, and mass sports would hardly be affordable. This article uses selected examples to give a brief overview of the possibilities and advantages that polymers offer in the modern sports arena. Jörn Korte Sports shoes can be adapted to...

Kunststoffe international, 2005-11-21, Process Combination: High-quality Surface from Injection Moulding and Reaction Process Machinery
Injection Moulding High-quality Surface from Injection Moulding and Reaction Process Machinery Process Combination. In a close development partnership and through synergistically merging injection moulding and reaction process machinery, a group of companies has developed a new process for producing parts with high-quality surfaces. This “SkinForm” technology opens up scope for completely new designs in vehicle interiors. The current tendency to incorporate a constant stream of designs and id...

Kunststoffe international, 2005-11-21, Process Integration: Short Cycles for Injection Moulded Microfluidics Parts
Process Integration: Short Cycles for Injection Moulded Microfluidics Parts Until now accurate casting of microfluidic structures in the injection moulding process has often been possible only with lengthy variable temperature thermal regulation of the mould. If these surface textures must still be sealed after injection, this usually takes place in an external covering station. Both lead to long cycle times. However, it is also possible to do this differently, as the following example shows. ...

Kunststoffe international, 2005-11-21, Process Technology: Plastic Automobile Windows
Special Plastic Automobile Windows Process Technology. Plastic is finding increasing use as a replacement for glass in automobile windows. An extremely dynamic market is developing, but one that places special requirements on materials, designs and production techniques. Success depends on an efficient logistical chain that addresses the product-specific requirements and the complex manufacturing processes. Christian Hopmann Sebastian Göbel Jan Forster With the introduction of the first Smar...

Kunststoffe international, 2005-11-21, Protective Control of Hot-Runner Systems
Protective Control of Hot-Runner Systems A Controller System with Error Diagnostics Prevents Damage to the Hot-Runner and Mould Thomas Jäger and Hans Hagelstein, Baden-Baden/Germany The new hot-runner controllers from Mold-Masters fulfil three functions: they achieve maximum control accuracy even with very difficult to control multicavity moulds; they offer maximum protection for the hot-runner system and prevent expensive production downtimes, and the phase angle control safeguards the se...

Kunststoffe international, 2005-11-21, Quality Testing: Criteria for Optical Sheet Inspection
Quality Testing: Criteria for Optical Sheet Inspection Web inspection systems in sheet extrusion allow the identification and avoidance of surface defects such as fish eyes, gels, occlusions, contaminants or insects. For the selection of a suitable inspection system, it is necessary to take into account the range of products and the demands they make. Rudolf Krampe Commercially available web inspection systems all appear similar at first glance. With the exception of laser-scanner-based sy...

Kunststoffe international, 2005-11-21, Rugged and Impact-resistant
Rugged and Impact-resistant Portable CD Boxes of TPV Portability is all the rage, but to make sure that such items as CD storage boxes keep their contents safe and unharmed if ever they are dropped, the manufacturer uses an impact-absorbing, crosslinked thermoplastic elastomer. The firm CD3 Storage Systems Inc. based in Texas, USA, has developed a particularly rugged, portable storage box for CDs. The housing of the new Discus range of boxes is made of a crosslinked thermoplastic elastomer...

Kunststoffe international, 2005-11-21, Screw Concepts: Influence of the Plasticising Unit on the Processing of PET
Screw Concepts: Influence of the Plasticising Unit on the Processing of PET The production of polyethylene terephthalate (PET) bottles can lead to the formation of acetaldehyde. Because acetaldehyde has a significant influence on the taste of the contents, it is important, when manufacturing bottles of PET, that the plasticising process should proceed very gently. The decisive factor here is the stress to which the material is subjected, because a local increase in temperature encourages the f...

Kunststoffe international, 2005-11-21, SEBS Compounds: Extremely Free-flowing
Thermoplastic Elastomers Extremely Free-flowing SEBS Compounds. Styrenic thermoplastic elastomers (TPE-S), especially SEBS compounds, were widely used until a few years ago in applications in which special haptic or design criteria had to be met. Further developments, both on the material and on the processing side, however, have seen them advance into technological applications that were previously the preserve of rubber or other TPE materials. Compared with other thermoplastic elastomers, th...

Kunststoffe international, 2005-11-21, Silicone Bonds
Silicone Bonds New Injection Moulding Concepts Herbert Kraibühler, Lossburg/Germany Over the past few years, a steady increase has come about in the use of injection-moulded silicone parts for technical applications. New injection moulding concepts are opening up additional fields of application. The increased use of silicone parts is essentially due to the latest developments in materials and peripheral equipment. This will serve to open up new fields of application in the future too: -...

Kunststoffe international, 2005-11-21, Simulation right through to Failure
Simulation right through to Failure Crash Simulations with Plastic/Metal Hybrid Parts Frank Lutter, Michael Münker and Martin Wanders, Leverkusen/Germany Structural parts for the automotive sector are being increasingly produced by hybrid technology. Newly-developed computation methods developed specially for crash simulation assist the design engineer with part design. Crash simulations provide a means of assessing the deformation behaviour, load-bearing behaviour and energy absorption ...

Kunststoffe international, 2005-11-21, Simulation Tools: Vibro-acoustic Design of Composites
Automotive Vibro-acoustic Design of Composites Simulation Tools. Multi-layered plastic composites are simply predestined for the complex requirements encountered today in lightweight structures. Moreover, in the future, modern lightweight applications will have to satisfy increasingly demanding vibro-acoustic requirements. Full exploitation of the acoustic potential of lightweight structures – especially fibre-reinforced multi-layered hybrid composites – requires suitable simulation tools for ...

Kunststoffe international, 2005-11-21, Solid Surface Materials
Solid Surface Materials Mineral-Acrylate Composites for Interior Design Horst Ulrich Reimer, Bad Homburg/Germany The invention of solid surface materials made of minerals and acrylic-acid ester has had a lasting impact on the world of design: such was the conclusion reached by a recent study carried out by a design association. According to the study, solid surface materials rank number three, directly behind personal computers and the internet. Solid surface materials, such as those bas...

Kunststoffe international, 2005-11-21, Somewhat Cooler in the South
Somewhat Cooler in the South Lower-than-expected Growth by the Italian Plastics Industry Italy's plastics industry did little to help the general upswing in the country in the year 2000. Hikes in raw materials prices also made life difficult for Italian processors and drove them to increasingly use recycled materials. The largest applications area - packaging - posted much lower growth than expected. The Italian plastics industry did not grow as much last year as the growth in gross do...

Kunststoffe international, 2005-11-21, Special Aspects of PET Film Extrusion
Special Aspects of PET Film Extrusion Special Polishing Method Ensures High Film Quality Peter Rieg, Bad Oeynhausen/Germany PET is a material which everyone immediately associates with blow-moulded bottles for soft drinks and mineral water. Due to its outstanding material properties and, not least due to falling raw material prices, PET is also gaining increasing importance in other sectors. PET film, in particular, which has low permeability to water vapour, oxygen and flavourings, in add...

Kunststoffe international, 2005-11-21, Specialty Oils for Extruder Gears: The Chemistry Has to Be Right
Extrusion The Chemistry Has to Be Right Sebastian Homborg Specialty Oils for Extruder Gears. The requirements to be met by extruder gears are increasing all the time. Consequently, the transmission oil is becoming ever more important. Synthetic oil grades can reduce power loss and wear on the gear. The result is cost savings and greater plant reliability. Extruder output is steadily being maximised in extrusion and compounding. At the same time, operators are trying to minimise their investment...

Kunststoffe international, 2005-11-21, Sports Equipment: Plastics at all Events
Sports and Leisure Plastics at all Events Sports Equipment. Of course, the ball is still round – but is it still made of leather? No, and it has not been for a long time. Basically, all sports equipment nowadays is made of high-tech materials – plastics. And polymers sometimes almost have to perform miracles if they are to help the athletes to victory. Putting together an ingenious combination of suitable plastic types is the well-guarded secret of all sports equipment manufacturers. Kristin...

Kunststoffe international, 2005-11-21, Statistical Pitfalls: Packaging - The Plastic Industry's Largest Customer
Packaging Packaging - The Plastic Industry's Largest Customer Statistical Pitfalls. Publications from the Federal Statistics Office list a number of performance figures for the plastic packaging sector and plastic production. These figures must be interpreted with great care because of the risk of, inter alia, counting factories twice and because without deeper analysis it is not possible to unambiguously categorise the products as sheet, film and hollow bodies. Haimo Emminger Plastic ...

Kunststoffe international, 2005-11-21, Strategies for Cooling Moulds
Strategies for Cooling Moulds An Overview with Practical Insights Martin Koch, Aachen/Germany Which cooling strategies are standard today and how do the various cooling systems perform in practice? The author visited plastics processors to find out. Injection moulding of thermoplastic materials is characterised by a complex interaction between materials, equipment and process engineering. First, the thermoplastic moulding compound to be processed must be melted in order that it may be in...

Kunststoffe international, 2005-11-21, Strong Upturn: Polycarbonate (PC)
Trend Report: Engineering Plastics Polycarbonate (PC) Strong Upturn. Following a period of subdued growth from 2001 to 2003, during which prices dropped dramatically, the global market for polycarbonate has been growing strongly since mid-2004. Thus, consumption is outstripping growth in capacity. Polycarbonate blends and film are becoming increasingly important, especially in the IT and automotive sectors. In 2004, some 15 million t of engineering thermoplastics were consumed worldwide. Arou...

Kunststoffe international, 2005-11-21, Styrene Polymers
Styrene Polymers Material Class with Wide Application Norbert Nießner, Ulrike Breiner and Achim Grefenstein, Ludwigshafen/Germany Styrene copolymers are an interesting and versatile product class used to produce high-quality components for automotive engineering, the electrical industry, the sports and leisure sector and packaging. In addition to commodities such as standard and impact polystyrene, highly transparent, high-impact materials can be obtained by anionic polymerisation. Through its p...

Kunststoffe international, 2005-11-21, Styrene-butadiene Block Copolymers: Combining Haptics and Design
Special Combining Haptics and Design Styrene-butadiene Block Copolymers. In a large number of sectors, transparent plastics are used as a means of product differentiation. Employing a styrene-butadiene block copolymer, for instance, it will even be possible to achieve transparent rigid/flexible composites in the future. Robert Huber The reasons why transparent plastics are used in packaging, housings and a large number of household, sanitary and cosmetics applications, as well as in electrical ...

Kunststoffe international, 2005-11-21, Tailor-made Engineering in Increasing Perfection
Tailor-made Engineering in Increasing Perfection Latest Hot-Runner Trends at Trade Fairs in 2001 Peter Wippenbeck, Aalen/Germany Customised hot-runner solutions are on the advance. Flexibility in manufacture and user friendliness have assumed maximum priority among suppliers. These trends were confirmed following visits to K2001 and Euromold. At the recent big trade fairs and exhibitions, a number of distinct trends were evident among hot-runner manufacturers: Plug-in versions are becomi...

Kunststoffe international, 2005-11-21, Technology Survey: Melt Filters for Compounding Polymers
Recycling Melt Filters for Compounding Polymers Wolfgang Dreu Technology Survey. One of the key process steps in the compounding of polymers by extrusion is filtration, namely the elimination of all types of foreign particles. The market offers a range of different technologies for this. To permit the correct choice of filtration system, it is important to know the state of the starting material and have an overall view of the process chain. Whether it makes technical and economic sense t...

Kunststoffe international, 2005-11-21, Testing Technology: Inline Measuring and Testing
Trade Fair Report Inline Measuring and Testing Testing Technology. Measurement and testing technology are being increasingly integrated into production, since quality data help users to optimise the manufacturing process, save raw materials and reduce costs. The goal of manufacturing with constant high quality is trivial to formulate. How production shops can approach this goal by exploiting the potential of testing technology and production monitoring was shown by a tour of K2004. Integrating...

Kunststoffe international, 2005-11-21, The Challenge of the Multi-Component Technique
The Challenge of the Multi-Component Technique Factors Governing Success of New Moulded-Parts Variants Gerhard Pötsch, Näfels/Switzerland The automatic sequence of operations possible with injection moulding process lends itself to the integration of different materials in one part. However, the different process variants afforded by the multi-component technique have to be supported by the appropriate machine technology. The multi-component technique has established itself in the inject...

Kunststoffe international, 2005-11-21, The Hot-And-Cold Solution
The Hot-And-Cold Solution Double Shot Mould for Parts Made of Thermoplastic Polymer and LSR Hansjörg Keusgen, Bahlingen/Germany Composites of thermoplastic polymer and liquid silicone rubber (LSR) are fascinating because of the wide variety of applications in which they can be used. Trouble-free processing of these totally disparate materials in one mould requires that the cavities of the semi-finished part be thermally insulated from those of the finished moulded part. Composites of har...

Kunststoffe international, 2005-11-21, The Italian Plastics Industry
The Italian Plastics Industry The Dark Clouds are Moving On Michael Kömpf, Munich/Germany Although the Italian plastics industry was rather pessimistic in the first half of 1999, plastics processing and machine-making equipment enjoyed sales growth of roughly 5 % in the second half. This upswing has continued in the first quarter of this year. Overall, companies in the Italian plastics industry expect 2000 to be a good year. Both Italy's and Germany's gross domestic products grew...

Kunststoffe international, 2005-11-21, The Production of Closures
The Production of Closures Production and Process Control Nikolaus Kudlik, Näfels/Switzerland Screw closures and flat closures constitute the main group of closures in terms of the quantities involved. Approximately half the 150 billion closures produced each year are made of plastic. Above-average growth is expected here through the substitution of metal closures. Closures have existed ever since the human race started collecting goods, storing them and protecting them. In the same way ...

Kunststoffe international, 2005-11-21, Thermoplastic Elastomers (TPE)
Thermoplastic Elastomers (TPE) Thomas Werner, Geneva/Switzerland, and Michael Fehlings, Bad Homburg/Germany Thermoplastic elastomers (TPEs ) have similar performance properties to elastomers but can be processed in the same way as thermoplastics. It is precisely this ease of processing that is prompting an increasing number of users to successfully replace crosslinked elastomers and flexible PVC with TPE. The TPE market is thus set to grow further over the years to come. Thermoplastic elas...

Kunststoffe international, 2005-11-21, Thin Bed Foaming for Door Covers
Thin Bed Foaming for Door Covers PU Process for In-Mould Foil Foaming Complete door sides have been made economically using in-mould technology with a PUR semi-hard foam. Special advantages include the surface texture and also good dust properties. For some years in the motor vehicle industry there has been a clear trend toward using materials of as high quality as possible. Not only in the luxury classes but also for middle class automobiles and for compacts focus is increasingly on quali...

Kunststoffe international, 2005-11-21, Tooling Technology and Mould-making: Trends in Mould-making
Tooling Technology and Mould-making: Trends in Mould-making What has been happening in this area in recent years? The author reviews developments in metal machining and materials technology, as well as hot-runner and tool technology, and their process and industry-specific applications. Peter Karlinger Severe competition, in particular the growing international market development, is challenging the industry to find ever more technically demanding solutions. New processes and the linking u...

Kunststoffe international, 2005-11-21, Tools: A Better Grip
Tools: A Better Grip The importance of the feel of a manual tool, power tool or gardening tool and the fact that it offers a firm grip should not be underestimated when it comes to product assessment. If a handle is uncomfortable and cannot be held securely in the hand, then this will affect the ease of operation and the efficiency of the tool. Designers and manufacturers must therefore pay attention to a whole range of factors – but above all to comfort, a secure grip and safety. Claude Mau...

Kunststoffe international, 2005-11-21, Top Performance
Top Performance Properties and Processing Aspects of TPU for High Performance Films Knud Fähndrich and Oliver Mühren, Lemförde/Germany Thermoplastic polyurethane elastomers (TPU) have by no means exhausted their potential for use in films. They offer outstanding mechanical properties with high extensibility over a wide temperature range, high puncture resistance and excellent abrasion resistance. Thermoplastic polyurethane (TPU) is a thermoplastic elastomer. It is formed essentially by a...

Kunststoffe international, 2005-11-21, Transparency in Injection Moulding
Transparency in Injection Moulding The Production of Highly Transparent Optical Mouldings - A New Challenge Erwin Bürkle, Bernd Klotz and Peter Lichtinger, Munich/Germany Optical mouldings represent an increasingly interesting field of application in plastics processing. Individual quality requirements for various kinds of mouldings can be met with the aid of specifically developed compression processes. Examples of optical mouldings that are becoming increasingly important for plastics ...

Kunststoffe international, 2005-11-21, Trends at the IAA: Shop Window for Innovations in the Motor Industry
International Motor Show Shop Window for Innovations in the Motor Industry Trends at the IAA. The mood of the exhibitors at this year's Frankfurt International Motor Show lay somewhere between hope and fear. The hope was that the many innovations can provide the necessary spark for the industry's spluttering engine. The exhibition also featured plenty of new developments on the materials side. Stefan Schlott 122 new vehicles – 80 of which were world premieres (front picture, Fig. 1) – ...

Kunststoffe international, 2005-11-21, Turbocharged Engines: Plastic Solution for Supercharged Air Pipes
Engineering Plastics Plastic Solution for Supercharged Air Pipes Turbocharged Engines. For automotive manufacture in the coming years the trend is clearly toward still more diesel engines. However, manufacturers face new challenges in order to comply with sharper environmental-protection regulations. Space and weight savings through compact and lightweight construction methods are only two of the key words. For example, such requirements can be fulfilled using supercharged air pipes made of the...

Kunststoffe international, 2005-11-21, Two-component Injection Moulding: New Hard-soft Combinations of POM and TPU
New Hard-soft Combinations of POM and TPU Two-component Injection Moulding. New hard-soft combinations of POM and TPU (TPE) are being produced by injection moulding. For this application, POM (Hostaform) copolymer grades with different impact modification and TPU (Elastollan) grades with varying degrees of hardness are being combined. The bond strengths of the different hard-soft combinations, as determined in a standardised tensile test, are evaluated and discussed. The results are compared wi...

Kunststoffe international, 2005-11-21, Two-component Micro Powder Injection Moulding: Three Special Processes in One
Injection Moulding Three Special Processes in One Two-component Micro Powder Injection Moulding. To produce multifunctional ceramic micro-parts, multicomponent, powder and micro injection moulding were combined in one process. This article describes the injection moulding of high-performance heating elements with adjustable electrical resistance. Powder injection moulding allows economic mass production of complex parts of metal and ceramic. Multicomponent injection moulding offers multifunctio...

Kunststoffe international, 2005-11-21, Two-component Technique for Cup Holders: Greater Ease of Operation
Greater Ease of Operation Two-component Technique for Cup Holders. The cup holder located on the central console of the Porsche Cayenne offers two convenient functions underneath its movable blind. The module securely accommodates beverage containers of different sizes and, if required, can also be converted into a spacious oddments tray. Fulfilling these demands requires a sophisticated design and a complex production technique. The basic support and tray for the cup holder module are made o...

Kunststoffe international, 2005-11-21, VDI-K Automotive Congress: Progress in Smaller Steps
VDI-K Automotive Congress: Progress in Smaller Steps With more than 1500 participants, this year’s International Conference on “Plastics in Automotive Construction” surpassed the organisers’ expectations. Experts from automotive construction, the suppliers industry, raw materials manufacturers along with politicians, researchers and scientists gathered to debate the opportunities and potential for plastics in automotive construction. Wolfgang Kircher Plastics are sought-after design materi...

Kunststoffe international, 2005-11-21, Walking Aids in TPV: Lightweight and Stable
Medical Technology Lightweight and Stable Walking Aids in TPV. Thermoplastic vulcanisates are increasingly being used in medical applications. Grips and feet in this material are used to upholster a stand-up and walking aid, thereby increasing its stability and giving it a more attractive appearance at the same time. After undergoing abdominal surgery that considerably limited his mobility, the American, Don Brown, decided to invent a device that would make it easier for patients to stand up a...

Kunststoffe international, 2005-11-21, Waterproof and Breathable
Waterproof and Breathable Multistage Stretching Process Generates Micropores in Hygienic Films Until now, hygiene films were waterproof but had limited air permeability, a fact which greatly impaired their wear comfort. A new process has been developed to overcome this problem: a multistage, monoaxial stretching to generate micropores in the film. This can lead to a ten-fold increase in air permeability. The hygiene industry is one of the industries with the highest growth rates and is the...

Kunststoffe international, 2005-11-21, Wear Protection: Use of PVD Coatings in Plasticising Units
Injection Moulding Use of PVD Coatings in Plasticising Units Wear Protection. PVD coatings are already used to a large extent in mouldmaking. Depending on the type of coating, they can provide improved protection against wear, better part release characteristics or lower friction in ejector guide bushings. In a new systematic approach, PVD coatings have been investigated with regard to their suitability for use in plasticising units. Christian Gornik The abbreviation PVD (physical vapour depo...

Kunststoffe international, 2005-11-21, Wear-resistant Needle Valves: Hot-runner Solutions for Extreme Demands
Tooling Hot-runner Solutions for Extreme Demands Wear-resistant Needle Valves. An injection moulding shop converted the production of a challenging two-component part from two machines with transfer of the preform to a single mould with a stack mould. One of the most important technical elements of the new system is a hot-runner system with needle valves. Thomas Adolph Processing unusual material combinations, such as a carbon fibre-reinforced, high-impact material together with a soft compone...

Kunststoffe international, 2005-11-21, Welcome to the Future
Welcome to the Future The Mother Project: Injection Moulding in the Year 2017 Davide Bonfadini, Brescia/Italy "Mother Project" is the name of a long-term research project being carried out in Italy. The partners in this project have allowed themselves to be guided by a vision, a vision of developing and manufacturing an injection moulding machine with an entirely new concept. Read on . . . The project, which was launched in 1999, is currently in the development phase: In co-opera...

Kunststoffe international, 2005-11-21, Welding Thermoplastic Elastomers
Welding Thermoplastic Elastomers Christian Bonten, Ernst Schmachtenberg and Carsten Tüchert, Essen/Germany Basically, parts made of thermoplastic elastomers are weldable. However, so far it is not clear what occurs in the inside of a welding seam of thermoplastic elastomer. This is being examined systematically in the context of a research project at IK2. Thermoplastic elastomers (TPE) are still a quite young group of materials that combine the advantages of thermoplastics and elastomers. O...

Kunststoffe international, 2005-11-21, What Hardens Surfaces
What Hardens Surfaces Powder-Metallurgical Materials as a Solution to the Problem of Mould Components at Risk of Wear in Injection Moulding Wolfgang Thierfelder, Andreas Hoffmann, Reutte/Austria, and Stefan Schmidt, Frank Ohm, Thomas Eulenstein, Lüdenscheid/Germany Wear on mould surfaces or mould components still constitutes a problem in injection moulding. By using annealed and surface-treated materials, an attempt is made to reduce the impact on the mould and hence on the surface finish ...

Kunststoffe international, 2005-11-21, Wide Area of Applications: Upward Trend for Thermoplastic Polyurethanes
Wide Area of Applications: Upward Trend for Thermoplastic Polyurethanes Thermoplastic polyurethane (TPU) has been used for the production of highly load-resistant functional and safety components in the automotive industry. An expanding range of properties and changing consumer requirements have been opening up new areas of application. Jürgen Hättig, Wolfgang Drube Since their initial industrial production in the sixties, TPU has undergone changes throughout several generations of automot...

Kunststoffe international, 2005-11-21, Wood Plastic Composites on the Right Track?
Composite Material Wood Plastic Composites on the Right Track? Wood Plastic Composites. The European market for wood plastic composites (WPC) is developing very dynamically in its own direction with high aesthetic requirements being specified for the finished products. Through systematic optimisation of formulations and processes, manufacturers are trying to find suitable approaches that will lead to the right solutions. Martin Bastian Itana Radovanovic Kersten Kurda The relatively new class of ...

Kunststoffe international, 2005-11-21, Wood-plastic Composites: Influence of Coupling Agents
Composite Material Influence of Coupling Agents Wood-plastic Composites. As binders between the wood fibres and polymer matrix, coupling agents improve the flexural strength, dimensional stability, impact strength and flow properties of wood-plastic composites quite considerably. They also significantly reduce the water absorption of the material. Martin Bastian Itana Radovanovic Kersten Kurda To obtain a good bond between wood fibres and polyolefins, the fibres are either chemically modified or...

Kunststoffe international, 2005-11-21, “It Depends on the Part”
“It Depends on the Part” Special Injection Moulding Processes in Automotive Engineering Helmut Potente, Hans-Peter Heim, Helmut Ridder and Elmar Kaiser, Paderborn/Germany A bewildering array of special injection moulding processes has become available. This article draws on practical examples to illustrate the range of processes currently used in automotive engineering. New applications will become possible through the appropriate combination of established process variants. The automoti...

Kunststoffe international, 2005-11-30, PTFE Multicomponent Compounds: A Material for Hard and Soft
Compounds A Material for Hard and Soft PTFE Multicomponent Compounds. Like auto makers, machine manufacturers are extending maintenance intervals as a means of cutting the life-cycle costs of their products. Through the continuous development of new fluoro polymer componds, sealants producers are gaining access to increasingly powerful materials. Thus, PTFE-bronze-carbon fibre systems combine such seemingly opposed properties as deformation resistance and low coefficient of friction. Erik Pe...

Kunststoffe international, 2006-01-09, Plasma Processes: The Functionalisation of Plastic Surfaces
Engineering Plastics The Functionalisation of Plastic Surfaces Plasma Processes. The plasma technology offers a wide variety of possibilities for functionalising surfaces to comply with the relevant specifications. Not only is the process more environmentally friendly than other methods, it also yields very high quality. This article describes the basic principles for a better understanding of this technology for industrial application. Ernst Schmachtenberg Andreas Hegenbart Through the applica...

Kunststoffe international, 2006-01-15, An Enterprise Preparing Itself: "Our Technologies Would Have Deserved More Courageous Renewal Also in Europe"
Interview An Enterprise Preparing Itself. After changing CEO Husky pushes into European core markets with new processes and a new organisational structure. Kunststoffe editor Clemens Doriat met Volker Neuber, vice-president sales and service for Western Europe with Husky, in the corridors of the Drinktec fair in Munich. "Our Technologies Would Have Deserved More Courageous Renewal Also in Europe" Volker Neuber about efforts and successes in the PET division and the strategy for transfe...

Kunststoffe international, 2006-01-26, Structuring and Ablating: Manufacturing Medical Products with Laser Technology
Special. Manufacturing Medical Products with Laser Technology. Martin Wehner Philipp Jacobs Structuring and Ablating. Polymers can be precisely structured by radiation from UV excimer lasers or line-tuned CO2 lasers. Even flexible materials like thin tubes can be drilled with high accuracy. Additionally, the laser technology is very well suited for the manufacture of prototypes and small series. As a sequential production method, laser technology is considered not to be a competitor to esta...

Kunststoffe international, 2006-02-21, Polyamide and ABS: Two Unlike Brothers Unite
Interior. Two Unlike Brothers Unite. Polyamide and ABS. The use of (PA+ABS) blend as a structural component in car interiors is a useful alternative to established materials and is also of interest from the cost point of view. Not only can this material satisfy the stringent technical specifications and the requirements on design variation, it can also help to significantly reduce system costs. Stefan Grutke. Most plastics are incompatible with each other. If two such plastics are blended toget...

Kunststoffe international, 2006-02-22, Cockpit Surfaces: Workplace and Living Room on Wheels
Interieur Workplace and Living Room on Wheels Cockpit Surfaces. The interior of today’s and tomorrow’s cars holds a great deal of potential for new surface materials and technologies. Depending on the comfort level, the spectrum extends from simple injection moulded applications to high-quality film techniques. Development of the required materials and processes must take into consideration function, aesthetics, safety, ecology and economics simultaneously. Bernhard Klein The interior of today...

Kunststoffe international, 2006-02-22, Interview: Changing Mould Construction
Interview Changing Mould Construction On 1 December 2005 Otto Männer AG celebrated its 40 year anniversary and at the same time dedicated the new enterprise centre at its headquarters in Bahlingen/Germany. With the purchase of the extension building also the new division Engineering & Consulting took up its work. Kunststoffe editor-in-chief Gerhard Gotzmann was present and spoke with the enterprise founder Otto Männer (OM) and his son Hans-Peter Männer (H-PM), the CEO and executive officer of O...

Kunststoffe international, 2006-02-22, Surface Technology: Opportunities for UV Curing
Surface Technology Opportunities for UV Curing Coatings. Driven by the need to cut costs, improve quality and reduce environmental pollution, intensive trials are now being carried out to assess the suitability of new effective painting methods for plastics used in automotive exteriors and interiors. The main points discussed here include the requirements for coating components, recent coating concepts and the advantages and disadvantages of UV curing. Guido Wilke Georg Meichsner Right into t...

Kunststoffe international, 2006-02-23, Mass-production Properties: The Possibilities and Limits of RP
Rapid Prototyping The Possibilities and Limits of RP Mass-production Properties. Will rapid technologies develop and become established within the near future to the extent that rapid parts will become widely used for functional verification in automotive prototypes or for the manufacture of very small production runs? The BMW Group’s Rapid Technologies Centre at its Research and Innovation Centre (FIZ) in Munich is certainly not the only team interested in this question. Jochen Töpker Innovati...

Kunststoffe international, 2006-02-23, Silicone Elastomers: An Attractive Alternative
Materials An Attractive Alternative Silicone Elastomers. In the meantime, they have become an absolute necessity in the automotive industry: since, in contrast to organic rubber compounds, silicone elastomers can withstand very high and very low temperatures for extended periods of time, while at the same time resisting ageing and weathering. They will continue to gain in importance with respect to future requirements. Bernd Pachaly Walter Strassberger Even without counting silicone airbag co...

Kunststoffe international, 2006-02-27, Automaking: Inspiration in the Interior
On the Spot. Inspiration in the Interior. Automaking. The Visteon plant in Berlin produces primarily plastic parts for automotive interiors. To meet the demanding requirements of the automobile industry regarding the surface quality of moulded parts and the safety of occupants, on the one hand, and utilise the competence of the supplier regarding its ability to provide solutions, on the other, the company employs a number of challenging processes. Clemens Doriat. Mercurial – the company histo...

Kunststoffe international, 2006-03-23, PET Beverage Bottles: External Bottle Coating in a Stretch Blow Module
Packaging. External Bottle Coating in a Stretch Blow Module. PET Beverage Bottles. A process for the plasma-assisted interior coating of PET bottles has already been widely introduced in industry. Working on from the success of this technology, a scalable plant for coating the exterior of bottles by means of microwave-assisted plasma polymerisation has been developed, built and tried out on a laboratory scale. Ernst Schmachtenberg, Dirk Binkowski. Over the past few years, the continuing substit...

Kunststoffe international, 2006-03-29, Injection Moulding: Flexible Manufacturing Concepts for Closures
Packaging Flexible Manufacturing. Concepts for Closures Injection Moulding Closures have to meet a wide variety of technical demands. A large number of functions must be integrated into a design that is both optically and haptically attractive. At the same time, the products are subject to severe cost pressures. These challenges can only be met by well-planned and innovative manufacturing concepts. Jochen Mitzler Erwin Bürkle In 2004, 400 billion closures were produced in West Europe, about 15...

Kunststoffe international, 2006-04-04, Market Launch: Foamed Liquid Silicone Opens New Doors
Injection Moulding Foamed Liquid Silicone Opens New Doors Market Launch. At the Arburg Technology Days, four cooperation partners introduced a new technology. For the first time, liquid silicone rubber can be foamed with physical blow-ing agents in the injection moulding process. The process opens the door to the produc-tion of parts with completely new properties. Sulzer Chemtech Ltd. recently presented a new variation of its Optifoam process. Devel-oped jointly with machine manufacturer Arb...

Kunststoffe international, 2006-04-25, Injection Moulding: Two-Component Pens Produced on an Automatic One-Component Machine
Special Two-Component Pens Produced on an Automatic One-Component Machine Gerhard Hulitz Injection Moulding. For reasons of economic and technical efficiency, Faber Castell produces its new two-component pens sequentially in two moulds on one machine. An in-house developed automation solution was needed to realise this method of production. The latest generation of ball-point pens and propelling pencils from Faber Castell, “Grip 2001", reduces the strain on users' fingers thanks to an...

Kunststoffe international, 2006-04-25, TPU Processing Aids: Polyethylene Extrusion without Melt Fracture
Additives Polyethylene Extrusion without Melt Fracture TPU Processing Aids. During polyethylene extrusion, melt instabilities can lead to surface defects or melt fracture. Additives based on thermoplastic polyurethane elastomers postpone melt fracture until higher shear rates. At the same time they improve melt release from metal moulds and dies. Polyethylenes are the world’s top-selling polymer group and demand for these materials is continually rising. One good reason for this is the cost-b...

Kunststoffe international, 2006-05-22, Component Design: Determining the Modulus of Elasticity in Compression via the Shore A Hardness
Testing. Determining the Modulus of Elasticity in Compression via the Shore A Hardness. Johannes Kunz, Mario Studer. Component Design. The modulus of elasticity in compression of elastomers with values of the Shore A hardness between 30 and 95 can be determined with a high degree of accuracy by converting these Shore A values. The formula derived for this purpose establishes a connection between the theoretical principles involved and the technical aspects of the Shore hardness test. The de...

Kunststoffe international, 2006-05-23, Innovative Potential: Additives Now and in the Future
Additives Additives Now and in the Future Innovative Potential. The use of additives to extend the range of properties offered by plastics has made a vital contribution to the success of these materials. Additives are important components in plastics formulations, which assist their processing and ensure a long service life. Additives modify, influence and safeguard service properties. They also achieve new effects and functions that open up considerable innovative potential. Rudolf Pfaendner...

Kunststoffe international, 2006-05-23, Trends and Products: Masterbatch Manufacturers in Germany
Masterbatches Masterbatch Manufacturers in Germany Trends and Products. The plastics processing industry is more and more achieving economy in production and customer oriented development through the use of masterbatches. There are masterbatch sources for almost all plastics and applications. At present in Germany there are fifty enterprises that produce and market masterbatches. Matthias C. Hund The use of masterbatches can no longer be excluded from the plastics processing industry. Permane...

Kunststoffe international, 2006-06-29, Hard-soft Combinations: Perfectly Matched
Elastomers Perfectly Matched Hard-soft Combinations. By combining thermoplastics that are dimensionally stable at high temperature, such as polyamide and PBT, with a crosslinking rubber component, multifunctional parts can be produced economically. Multicomponent injection moulding and the similar fast cycle times of both materials are key factors in this success. Dirk Achten Maik Schulte Hard-soft combinations of a thermoplastic with a thermoplastic elastomer (TPE) produced by multicompone...

Kunststoffe international, 2006-06-29, On-line Control: Process Control for Thermosetting Plastic Materials
Reactive Processing. Process Control for Thermosetting Plastic Materials. Wolfgang Stark, Christian Kürten. On-line Control. Dielectric sensors monitor the cross-linking process right inside the mould during injection. The state of curing is observed continuously, deviations are recognised and cycle times optimised. Free-flowing thermosetting plastic materials, especially in the field of highly demanding applications, have asserted themselves against their thermoplastic competitors [1–4]. ...

Kunststoffe international, 2006-07-04, Automotive Engineering: High Soft-touch Quality in One Single Process
Injection Moulding. High Soft-touch Quality in One Single Process. Automotive Engineering. Four well-known companies have jointly reduced the multi-stage process for the production of soft-touch car interior components to a combined single-stage process (“Dolphin”) utilising injection moulding and foam moulding. One of the future-oriented projects to be presented at the Engel Symposium in the middle of May was undertaken jointly by four companies: - the raw material manufacturers BASF, Ludwigs...

Kunststoffe international, 2006-07-12, Automobile Interiors: Soft Skin, Hard Core
On the Spot. Soft Skin, Hard Core. Clemens Doriat. Automobile Interiors. Moulding 2-component parts with a soft surface without expensive multi-component machinery – the Monosandwich process makes it possible. Under certain conditions and with clever part design, the end user can “strike several flies with one blow”. In 2004, shortly before presentation of the preproduction version of a car for nonsmokers to the public: a manager from the executive level sits on the rear seat of the new Ford ...

Kunststoffe international, 2006-08-31, PU Technology: Discovering New Possibilities
Market and Management. Discovering New Possibilities. Michael Schlumm. PU Technology. Hennecke GmbH, St. Augustin, held a festive opening ceremony for its new Composite Spray Moulding (CSM) Centre, to which a large number of partners and guests were invited. The company’s new Technology Centre, covering more than 300qm, has been designed to reproduce series production conditions, thereby enabling the potential of spray moulding technology to be investigated and new product ideas to be bro...

Kunststoffe international, 2006-09-05, Interview with Sebastian Karrer: “Our Turf Solves a Problem of Modern Football Arenas"
Sports and Leisure The use of artificial turf for football is becoming more and more important through recent developments in polyolefin fibres and strips and filler materials. Gudrun Klein, responsible for materials and applications at Kunststoffe, spoke with Sebastian Karrer, managing director of Polytan Sportstättenbau GmbH, Burgheim/Germany, about the advantages of artificial turf systems compared with natural ones. “Our Turf Solves a Problem of Modern Football Arenas" Sebastian Karrer...

Kunststoffe international, 2006-09-08, Carrier Film: New Possibilities for Decorating Thanks to 3-D Dye-Sublimation Printing
Elastomers. New Possibilities for Decorating Thanks to 3-D Dye-Sublimation Printing. Christophe Chervin Carrier Film. With the aid of the new 3-D colour sublimation printing, POM, PBT and polyamide objects with complex surface geometries can now also be printed. This is made possible by two newly developed carrier materials that conform well to such surfaces. The first commercial applications employing this new technology are now appearing on the market. A new technology from DuPont has now m...

Kunststoffe international, 2006-09-26, Material Handling: Basis of Product Quality
Processing Pre-stage. Material Handling as a Basis of Product Quality. Johannes Wortberg, Marcel Großmann. Material Handling. In recent years, economic development has compelled some plastics processors to re-consider and re-evaluate the peripheral equipment of material supply and preparation. Integration of all surroundings into the automated production process as well as higher flexibility have already been accomplished in many plastics processing factories. When it comes to stepping up e...

Kunststoffe international, 2006-09-27, Interview with Hans Wobbe: “Permanent Productivity Increases”
Interview “The leading market position of Engel is attributable to two factors. On the one hand, the high-technology business that requires continuous development, and, on the other, the production of large numbers of machines that makes financing the cost-intensive developments possible,” according to Engel’s website. These are the responsibilities of Dr.-Ing. Hans Wobbe, Managing Director of Engineering at Engel Holding GmbH. Kunststoffe’s editor, Clemens Doriat, met with him for a conversati...

Kunststoffe international, 2006-09-27, Processes in Synergy: Hot-plate Welding for High-melting Polymers
Joining Technology Hot-plate Welding for High-melting Polymers Processes in Synergy. Hot-plate welding reaches it limits with engineering and high-performance polymers. The melt sticks to the hot plate, increasing cleaning work and reducing weld seam strength. With ultrasonic assistance, hot-plate welding can be made into a mass-production method for these polymers, with a wide process window and high process stability. At the same time, a significantly higher weld seam strength and quality are...

Kunststoffe international, 2006-09-27, Processing of Semi-Finished Products: Air or Vacuum?
Thermoforming Air or Vacuum? Processing of Semi-Finished Products. New process variants such as twin-sheet forming and IMG are competing with related production processes. Developments in machine and control technology coupled with a high degree of automation are reducing cycle times and increasing cost efficiency. Thermoforming is the preferred production method for both very thin-walled thermoplastic components at one end of the size spectrum and large flat parts at the other. Simple, fast mat...

Kunststoffe international, 2006-09-27, Trend Outline: Integration and Intelligence
Injection Moulding. Integration and Intelligence. Herbert Kraibühler. Trend Outline. Injection moulding is going to continue its way towards the “intelligent” machine. A holistic view of the machine, mould, material and process will help machine manufacturers make production safer, easier to be handled and more cost-effective. In particular, increased synergetic integration of individual production methods into intelligent overall systems with one control unit represents the future of high-wa...

Kunststoffe international, 2006-10-27, Pedestrian Protection: Crumple Zones for Pedestrians
Safety Technology Crumple Zones for Pedestrians Pedestrian Protection. The countdown to pedestrian protection continues. Since October 2005, all newly approved vehicles have had to incorporate suitable protective systems. But the industry is already looking ahead to the second phase, which will apply from 2010. Stefan Schlott Pedestrian protection continues to be a current focus of research in car manufacturers’ safety departments (Fig.1). The aim is to reduce the forces impacting on the leg, ...

Kunststoffe international, 2006-10-30, Injection Moulding: A Mirror Finish with no Visible Weld Seams
Tooling A Mirror Finish with no Visible Weld Seams Injection Moulding. For the monitor frame for the Mercedes Benz S and R classes, Weber Kunststofftechnik took the strategy of concealing weld seams by conformal thermal management. This places strict demands on the highly polished mould. Thomas Cronau Henning Schmidt Rear passengers in the Mercedes-Benz S and R Classes can watch movies or play computer games on seven-inch monitors in the headrests on the driver and front passenger seats. As s...

Kunststoffe international, 2006-10-30, Material Development: Polycarbonate Lenses for LED Lighting
E+E Technology. Polycarbonate Lenses for LED Lighting Martin Döbler, Frank Schiemann. Material Development. Light emitting diodes (LEDs) are regarded as the illuminants of the future. They must be fitted with customised lenses to optimise their luminance. For this purpose, polycarbonate is a suitable material. At present, the development of expertise in special materials and techniques is the focus of intensive effort. In the mid-1990s, LEDs capable of radiating white light were produced for...

Kunststoffe international, 2006-12-06, Corporate Strategy: Global Thinking and Acting in Corporate Technical Operations
Market and Management Global Thinking and Acting in Corporate Technical Operations Corporate Strategy. Progressive globalisation is not only making global business and management-oriented thinking necessary but is also increasingly affecting the strategy and actions of those responsible for corporate technical operations. It is no longer opportune for internationally positioned companies to act solely in a European dimension, let alone just a German one. This can even be problematic. Ralf Ack...

Kunststoffe international, 2007-01-22, Also for High Temperatures
Also for High Temperatures Chemically Cross-linked TPE-V New types of elastomeric compounds combine the good processing characteristic of TPE-S (styrene block copolymer) materials with the good performance of TPE-V (EPDM/PP) at elevated temperatures. The combination of properties makes TPES-V compounds a possible alternative to the rubber formulations used to date. And not only for previous applications in the automotive industry. Frieder Vielsack, Jörg Sänger, Markus Beitzel The growth rat...

Kunststoffe international, 2007-01-22, Complex Moulds for Foam
Complex Moulds for Foam PU Mould Technology Car interior trim parts must meet exacting specifications and be economical to manufacture. For this, polyurethane processing moulds offer complex possibilities for integrating functions and parts. Designing a part for production requires close cooperation between everyone involved right from the concept phase. Jürgen Lause The requirements on the quality of vehicle interiors have grown continually in the last ten years. In the industry, there has ...

Kunststoffe international, 2007-02-13, Filling of Flexible Packaging
Filling of Flexible Packaging Article Optimisation Compared to rigid packaging, flexible packaging for nutrient solutions offers a number of benefits. To date, the disadvantages versus rigid packaging have been the considerably higher packaging and processing costs. Using a new technical solution, a lower port fitting (port spout), through which the pouch can be filled like a bottle in a continuously operating filling machine, is welded in just before filling. The packaging is then closed by...

Kunststoffe international, 2007-02-13, Injection Moulding Small Transformers?
Injection Moulding Small Transformers? Magnetically Soft Composites Injection moulded magnetically soft plastic parts have not yet been very widely investigated. Magnetically soft compounds were therefore injection or compression moulded to produce magnetically soft cores for coils. Cores filled with 70 vol.-% iron achieve good magnetic characteristics and therefore become attractive for technical applications in the low-frequency range of 50 to 60Hz. Mathias Anhalt Bernd Weidenfeller Si...