L-Block - PE-E - JSP Corporation

Plastics Technology, 2004-03-30, New TPE Compounder Debuts in U.S.
Formulating thermoplastic elastomers is a highly customized business. In its first three months of operation, Kraiburg Corp. in Duluth, Ga. has made some 30 custom products and another 20 standard gra...

Plastics Technology, 2006-08-07, New Olefin Block Copolymers Stretch TPE Processability and Cost Performance
A developmental family of novel olefin block copolymers (OBCs) from Dow Chemical Co. is lauded as a breakthrough in olefinic thermoplastic elastomers due to a unique block structure, which reportedly ...

Kunststoffe international, Award-Winning Packaging Solution ‧Increases Productivity
A solution, which is unique in Europe, significantly increases productivity and comprises the production from a 12+12 stack mold with fully automated in-mold labeling and removal with visual 100 % inspection of the parts. The process significantly increases productivity compared to conventional tooling solutions. The Thuringian mold making specialist roth was responsible for the design and construction of the stack mold. Ewikon supplied the customized valve gate hot runner system. Packaging man...

Kunststoffe international, Diverse Shapes and Applications
Styrenics can be polymerized using different technologies and it can be modified with a range of copolymers. The resulting plastics offer a wide range of properties allowing to customize them for different applications. ‧Because of this range of properties they are suitable for many industries. Strong demand is for example driven by the automotive industry, healthcare and the packaging industry. Styrenic polymers are amongst the economically most important plastics. They combine benign processin...

Kunststoffe international, Excellent Resistance at Reduced Weight
The transfer of foam injection molding from thermoplastic to thermoset processing has not yet been implemented in industrial practice. IKV Aachen has investigated this transfer and has precisely analyzed the economic efficiency of the process and the potential for lightweight construction. For years, politicians have been urging the automotive industry to reduce the CO2 emissions of its fleets – and thus above all the vehicle weight – [1–3]. At the same time, a trend towards increased temperatur...

Kunststoffe international, Maintaining Clarity Long-Term
Transparent plastics are used in medical technology for disposable articles such as catheter accessories, blood/plasma separators, thorax drainage sets, and medical filter and device housings. Since they are being exposed to increasingly aggressive solvents, disinfectants and drugs (for example new cancer drugs), these plastic articles have to be comprehensively tested for their chemical resistance. Plastics in medical technology must be resistant to environmental effects throughout their servic...

Kunststoffe international, Paying Attention to Layers in-between
Continuous Compression Molding (CCM) technology can be applied to multilayer solutions and is referred to as Continuous Compression Molding Multilayer (CCMM). In addition to the usual benefits of CCM it offers further advantages over competing technologies. In packaging applications, compression technology makes it possible to use minimal quantities of barrier material, thus combining excellent performance with low raw ‧material costs. The Continuous Compression Molding Multilayer (CCMM) process...

Kunststoffe international, Putting Hybrid Components to the Test
The different thermal expansion of plastics compared with metals makes it difficult to design components that combine both materials. A new test procedure simulates in a time lapse the aging process of plastic-metal hybrid components when temperatures change. Using two contrasting test procedures, reliable information can be ‧derived to assist in the designer. Metal or plastic? Traditionally, many automotive components are made from either one or the other material. But in the field of e-mobilit...

Kunststoffe international, Quickly and Gently around the Bend
Consider this paradox: sensitive PET is particularly demanding when being processed because it undergoes rapid thermal and mechanical degradation, yet when PET preforms are being produced scant attention is paid to designing the all-important hot runner to suit the individual product. Much more often, a manufacturer will use several cold halves and a hot one and produce articles weighing from 6 to 40 g. Darmstadt University of Applied Sciences, Germany, and mold specialist MHT conducted a resear...

Kunststoffe international, Reactive Extrusion of TPU
The simple replacement of petroleum-based components with renewable ‧alternatives in a well-established reactive extrusion process is a promising route to more environmentally friendly thermoplastic polyurethane ‧elastomers (TPU). However, this requires a comprehensive understanding of the interactions between chemical reactions and material flow within an extruder, as well as a thorough understanding of the effects of heat and shear on polymerization and melt processing. Driven by the strategy ...

Kunststoffe international, Semi-Crystalline, and yet Thermoformable
Ultra high performance polymers such as polyaryletherketones (PAEK) are typically not thermoformable for thick gauge applications because of their semi-crystalline nature. Specially developed PEKK grades now allow processing in this method. These can be used to produce large semi-crystalline PAEK parts with large wall thickness exhibiting extreme mechanical, chemical and flame retardant properties. Polyaryletherketones (PAEK) are used in technically challenging industry sectors, e. g. aerospace...

Kunststoffe international, The Potential of Redesign and Part Consolidation
Hybrid production chains have been increasingly in the spotlight in recent years. This also applies to the ‧combination of conventional manufacturing and additive processes in tool construction. With the example of an injection molding tool, it is shown how mold inserts produced by additive manufacturing can greatly shorten cycle times, and thereby significantly reduce unit costs. The important thing is to find a suitable combination of processes from the variety available. Over recent years, ad...

Kunststoffe international, 2005-11-21, Automating Tape Production
Automating Tape Production A Novel Doffing System Reduces Labour Costs and Waste Peter Schmalholz and Arnold Sillipp, Vienna/Austria To meet increased demands for quality and waste reduction, as well as to counter increasing labour costs, Starlinger has developed a new concept for partly automating polyolefin tape production with economic advantages for the subsequent weaving process. The new system reduces labour costs and waste while increasing loom efficiency and quality. In addition,...

Kunststoffe international, 2005-11-21, Automotive Applications: Thermosets Get Going
Automotive Applications: Thermosets Get Going Metals, thermoplastics and thermosets are all competing against each other in the keenly-contested automotive sector. Thermosets have good prospects for under-the-bonnet applications, in particular, since they combine resistance and stability with the possibility of cost-efficient production. Eva Bittmann The use of plastics in cars not only permits weight reductions and hence energy savings when the car is in service but also makes for more co...

Kunststoffe international, 2005-11-21, Blown Film Extrusion Today
Blown Film Extrusion Today Versatility and Flexibility are Required Jens Spirgatis and Johannes Wortberg, Essen/Germany Because of the increasing demands being imposed on film products, e. g. in the area of food packaging, a continuing trend towards coextruded film is evident. In addition, the market requires high production flexibility on the part of film manufacturers. As a result of this, new requirements have arisen in relation to plant technology, to which the machinery manufacturers ...

Kunststoffe international, 2005-11-21, Broad Spectrum
Broad Spectrum Krauss-Maffei's Duroplast Forum Well Visited About 400 visitors, almost half from foreign countries, found Krauss-Maffei Kunststofftechnik's Duroplast Forum in Munich/Germany at the end of May unusually appealing. In addition to the machine demonstrations there was a symposium with altogether 20 lectures presenting a cross section of today's thermosetting polymer technology. In 1998 Krauss-Maffei took over Fahr Bucher Service GmbH, Gottmadingen/Germany, with all ...

Kunststoffe international, 2005-11-21, Calcium Silicate as a Functional Filler: Wollastonite – a High-performance Filler
Additives Wollastonite – a High-performance Filler Calcium Silicate as a Functional Filler. It is only in the last 30 years that the plastics industry has discovered the mineral, wollastonite, which was previously used mainly in the ceramics industry. The more refined wollastonite powders have gained considerably increased importance as reinforcing materials for plastics. Bettina Nolte-Ernsting For a long time now, fillers have ceased to be a simple means of extending plastics compounds to redu...

Kunststoffe international, 2005-11-21, Case Study (2): Hot-Runner Solution for a Thermostat Rotary Knob
Tooling Hot-Runner Solution for a Thermostat Rotary Knob Case Study. With multicomponent technology it is possible to meet requirements such as ensuring that the lettering on a part is abrasion resistant in constant use and that the parts can be produced in a single operation, without secondary work for handling and marking. The prerequisite for obtaining the desired results is close cooperation between the mould maker, designer, injection moulder and hot-runner supplier. Dirk Paulmann Complex ...

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

Kunststoffe international, 2005-11-21, Case Study (4): Hot-Runner Solution for a Spectacle Case
Tooling Hot-Runner Solution for a Spectacle Case Case Study (4). The question of whether a high-quality designer surface can be obtained in injection moulding depends on a variety of factors. The design of the part, the choice of polymer, the mould concept, the gate system and the injection moulding process all have an effect on the surface quality. The project described here gets to the bottom of the interrelations. Dirk Paulmann Injection moulded plastic parts are now replacing metals and o...

Kunststoffe international, 2005-11-21, Case Study: Hot-Runner Solution for an Electronics Coil
Tooling Hot-Runner Solution for an Electronics Coil Case Study. What points have to be observed in designing the hot-runner system for producing an electronic part of glass fibre-reinforced PA? This article is the first of a six-part series on practically tested solutions, which will run until the end of the year. Dirk Paulmann A modular hot-runner system allows the system to be adapted to specific production requirements while at the same time keeping lead times short. By viewing the project in...

Kunststoffe international, 2005-11-21, Combinations Enhance Performance Many Times Over
Combinations Enhance Performance Many Times Over Trends, Tendencies and Perspectives in Multi-component Injection Moulding Ansgar Jaeger, Schwaig/Germany While the mould technology and process engineering for multi-component injection moulding are becoming ever more complex, the machines can be configured in an increasingly flexible manner on a modular basis. Future opportunities for multi-component injection moulding will be based first and foremost on the combination of different approac...

Kunststoffe international, 2005-11-21, Composite Parts: Flexibility in Rigid/Flexible Combinations
Composite Parts: Flexibility in Rigid/Flexible Combinations In the production of rigid/flexible combinations, either thermoplastic elastomers (TPE), rubber, or liquid silicone (LSR) are used as the flexible component, depending on the case in question. As a specialist producer of multicomponent injection-moulded parts, Weigelt has a great deal of experience in processing all three materials. There are a number of challenges to be mastered when it comes to the application technology, however......

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, Compounds and Masterbatches: Revival of Research and Development?
Compounds Revival of Research and Development? Compounds and Masterbatches. Once again, over 80 exhibitors presented compounds and masterbatches at the K 2004. The selected strategies of the individual companies are as varied as the challenges facing the industry: tailoring the properties of plastics to their respective applications. For the first time, several global players were not present in Düsseldorf, while family-run companies emphasised that participation in the K-fair was meaningful...

Kunststoffe international, 2005-11-21, Control Functions with Artificial Intelligence
Control Functions with Artificial Intelligence AI Brings Advantages in Precision Injection Moulding with All-Electric Machines All-electric injection moulding machines have proven that the electromechanical drive concept has advantages over hydraulic machines for the production of precision parts with thin walls and short cycle times. This article describes the capabilities of all-electric machines and where their advantages lie. Michael Kerber, Neuss-Grimlinghausen/Germany The all-elect...

Kunststoffe international, 2005-11-21, Convertible Top Systems: Convertible Top – Lightweight and Made Easy
Convertibles Convertible Top – Lightweight and Made Easy Convertible Top Systems. Innovative and economic solutions can be developed by using plastics for convertible tops and associated systems. Particular advantages are in possible function integration and weight minimisation. In the article some exemplary applications are described. Thomas Lemckau Oliver Moritz The quantities of convertible vehicles produced can vary from 20000 to 200000 units depending on vehicle class with running times bet...

Kunststoffe international, 2005-11-21, Cooling Injection Moulds
Cooling Injection Moulds Effective Cooling of Very Small Areas Siegfried Stitz, Klaus Schink and Manfred Popp, Würzburg/Germany The ways and means of cooling mould cross sections less than 5 mm thick are described and compared. Equipment to measure cooling efficiency is available to study the cooling effect of different cooling systems. In medium-sized moulds today, easily accessible mould regions with large cross sections are cooled by cooling channels 8 to 10 mm in diameter that are in...

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, Cutting Foams: Foam-Splitting-Machine with Network Capability
PUR Technology Foam-Splitting-Machine with Network Capability Jürgen Speck Cutting Foams. Complex cutting lines for moulded parts in polyurethane or other foams are made up of a number of separate machines which, in the ideal case, ought to be able to communicate with each other. Data exchange on horizontal splitting machines has now been implemented on the operating unit in a direct and straightforward manner for the first time, via Ethernet. Arm rests and backrests for upholstered furnitur...

Kunststoffe international, 2005-11-21, Cycle time reduction: Linear Motion Technology Accelerates Production Exponentially
Cycle time reduction: Linear Motion Technology Accelerates Production Exponentially Bosch Rexroth AG substantially accelerated manufacture of thin walled injection moulded parts in its Schweinfurt/Germany works using an automation system from the handling specialist Hekuma GmbH. Hekuma uses Rexroth’s linear motion and assembly technologies as core components for the high-speed unloading robot. Torsten Kirchmann The highest quality and 24 hour delivery capability are crucial competitive adv...

Kunststoffe international, 2005-11-21, Demand Continues to Rise: Polystyrene (PS)
Trend Report Commodity Plastics Polystyrene (PS) Demand Continues to Rise. Polystyrene still ranks among the quantitatively most important thermoplastics and after PE, PP and PVC is invariably in fourth place. Pushed by price pressure and price volatility, there is some movement on the polystyrene market, and the industry continues to consolidate. In addition product and procedure innovations will have high value nevertheless. Hans-Dieter Schwaben Consumption of PS in Europe decreased somewh...

Kunststoffe international, 2005-11-21, Die Optimisation: Flexible Die Walls
Die Optimisation: Flexible Die Walls Flexible die walls that can be adjusted to requirements are already to be found in some applications. Flow-channel walls that can be adjusted particularly during production can lead to potential savings and offer new process-engineering possibilities. Heinz Gross There must be few plastics processors who have not wished at least once that they could change the geometry of a flow channel during running production in order to quickly and cost effectively ...

Kunststoffe international, 2005-11-21, Dimensional Stability and Impact Strength
Dimensional Stability and Impact Strength (PC+ASA) Blends for Automotive Body Panels Martin Weber, Heiner Görrissen and Reinhard Jakobi, Ludwigshafen/Germany Blends based on polycarbonate (PC) and acrylonitrile-styrene-acrylic ester (ASA) are noted for their good weatherability and processing stability. A new product with improved flowability and toughness has been developed for the field of automotive body panels. Applications in the field of automotive body panels (title photo) constit...

Kunststoffe international, 2005-11-21, Direct Compounding: New Directions in Plastics Processing
Special New Directions in Plastics Processing Direct Compounding. Process steps that normally occur separately during compounding at the resin supplier and during processing at the producer of semi-finished or finished goods are combined in direct extrusion and in the injection moulding compounder. The additional effort and expense incurred by the processor are considerable and must be offset by cost savings for the raw materials as well as by the benefits resulting from increased flexibility a...

Kunststoffe international, 2005-11-21, Editorial: Light and Versatile
Light and Versatile Just in time for the start of the new millennium, plastics packaging has become the leading packaging material, pushing paper/paper board/cardboard to second place. Correspondingly, the packaging segment is the main consumer of plastics and the main customer of the plastics producing industry. If machinery and equipment used for producing plastics packaging materials were to be included in this balance sheet, the significance of this particular area of application for our e...

Kunststoffe international, 2005-11-21, Efficiency Comparison: Microspheres – a Universal, Effective Blowing Agent
Efficiency Comparison: Microspheres – a Universal, Effective Blowing Agent Expandable microspheres are microscopically small spheres with a thermoplastic outer skin and a filling of condensed gas. They expand on heating. Used as a blowing agent in thermoplastics, they can reduce the initial density of the plastic by up to 40 percent. Comparative measurements show how material and process parameters influence the efficiency of the microspheres. Lena Jönsson, Klaus-Rüdiger Rosskothen E...

Kunststoffe international, 2005-11-21, Elastomers
Elastomers Economic Situation and Observed Trends Werner P. Lauhus, Münster/Germany World consumption of synthetic rubber is expected to grow at +2.9% per year by 2005. Of this, China expects to see the biggest growth at +8.4%. In 2000, the synthetic rubbers with most growth in demand were EPDMs, owing to the increased consumption of technical rubber goods, and butadiene rubber, because of increased use in tyre applications. Germany is one of the world’s biggest technology motors in the ...

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, 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, Filter Cups Made from Polyamide: Transparency for Water Filters
Engineering Plastics Transparency for Water Filters Filter Cups Made from Polyamide. Modern filter systems would be inconceivable without plastics. The transparent filter cups in water filters made by Carbonit Filtertechnik are produced from Grilamid, a thermoplastic polyamide 12 that absorbs virtually no water and is approved for food and drinking-water contact applications. Peter Westerbarkey Engineering plastics play a key role in professional filter systems. They allow the greatest possible...

Kunststoffe international, 2005-11-21, Flat-film Extrusion Lines
Flat-film Extrusion Lines Flexible and Innovative Plant Concepts Ulrich Berghaus, Troisdorf/Germany Flat films, often high-quality films based on PP, are used for packaging consumer goods and in the office, medical, hygiene and technical sectors. Globalization and increasing product quality requirements have changed the market situation in the plastics industry. Machinery manufacturers must react to this in a flexible, innovative way with cutting-edge plant designs and state-of-the-art tec...

Kunststoffe international, 2005-11-21, Flexible Quality Assurance
Flexible Quality Assurance Portable Tool for Measuring Parts and Assemblies Ralf Steck, Friedrichshafen/Germany Tolerances are tight in automotive engineering - both in technical terms and when it comes to finances and time. As a system supplier for roofs and sunroof and door systems, Meritor LVS also has to operate within the tight constraints imposed by the automobile manufacturers. The company, a subsidiary of the US Meritor, uses a SilverArm from Faro for the quality assurance of produ...

Kunststoffe international, 2005-11-21, Fluid Injection Technique: Manufacture of Multilayer Media Lines
Injection Moulding Manufacture of Multilayer Media Lines Fluid Injection Technique. Gas-assisted and water-assisted injection moulding technique allow channels to be formed in the molten regions of an injection moulded part by displacing the molten core into cavity regions that are at first unfilled or are additionally opened. New possibilities for reducing costs and producing innovative plastic hollow bodies can be achieved by combining this process with multicomponent injection moulding. Wal...

Kunststoffe international, 2005-11-21, Formwork Elements: Building System with High Future Potential
EPS-Processing Building System with High Future Potential Klaus Unterleutner Alexander Doskocil Formwork Elements. Insulating concrete forms are special components made of expanded polystyrene that are put together on the building site and filled with concrete afterwards. They show good insulating characteristics and have a high market potential. The migration of the production locations of internationally active enterprises in the consumer electronics range towards the east continues to pro...

Kunststoffe international, 2005-11-21, Friction Behaviour of Thermoplastics
Friction Behaviour of Thermoplastics Test Method to Determine the Friction Coefficient between Plastics and Moulding Surfaces René Muschalle, Guimarães/Portugal The friction behaviour of plastics in contact with the surfaces of injection moulds is a key factor that must be considered in designing the ejection system. As part of the "Mouldfriction" programme at the University of Minho, Guimarães/Portugal, a test apparatus was developed that simulates the conditi...

Kunststoffe international, 2005-11-21, Functionality is the Key Factor
Functionality is the Key Factor Plastics Drive Medical Progress Martin Weller and Peter Eyerer, Stuttgart/Germany The ever increasing functionality of medical products and, in parallel with this, the mounting complexity of such articles are making a significant contribution towards raising the value added in the use of plastics for medical applications. This, in combination with the enormous pressure on costs in the health care sector, is providing the driving force for innovative developm...

Kunststoffe international, 2005-11-21, Gas-assisted Injection, Temperature Control, Foaming: Industrial Gases as Aids During Injection Moulding
Injection Moulding Industrial Gases as Aids During Injection Moulding Gas-assisted Injection, Temperature Control, Foaming. The use of nitrogen or carbon dioxide for injection moulding applications provides noteworthy economic and technical benefits and, for these reasons, continues to grow. This article describes areas where the potential for industrial gases can be developed further. Ursula Resgren Andreas Praller The range of possible applications for industrial gases in injection mouldin...

Kunststoffe international, 2005-11-21, Good is Not Enough: From Initial Idea to Successful Product
Innovation Management From Initial Idea to Successful Product Good is Not Enough. The chances of success for innovations and thus long-term economic growth are basically determined by favourable underlying economic and political conditions. It is particularly important for the marketing units of the companies to recognise which way technological developments are going and to correctly appraise the market opportunities. Stefan Marcinowski Chemical innovations make our life more pleasant and c...

Kunststoffe international, 2005-11-21, HALS Light Stabiliser: Light Stabilisation and More
Additives Light Stabilisation and More HALS Light Stabiliser. In addition to the primary stabilising action of HALS compounds, secondary effects often play a key role in selecting the best stabiliser for a given application. The lower the interaction with other additives or substances in the processing or end-use environment, the better the stabilising and processing properties can be. Alban Glaser Simon Schambony The range of oligomeric HALS (Hindered Amine Light Stabilisers) compounds is almo...

Kunststoffe international, 2005-11-21, High Fitting Accuracy
High Fitting Accuracy Moulds for Aircraft Components Made of Prepreg Materials Thomas Nägeli, Güttingen/Switzerland, Reinhold Krause, Burgdorf/Switzerland, Karl Heinz Sprenger and Gerhard Musch, Vaihingen/Enz, Germany In the course of the work carried out in the aviation industry to increase performance, very specific aerodynamic and structural improvements have to be made to the individual components used in aircraft construction. This results in correspondingly high demands on the manufa...

Kunststoffe international, 2005-11-21, High-Grade Insulation
High-Grade Insulation TPU for High-Performance Cables Alfons Bertels, Lemförde/Germany The automotive engineering sector, in particular, calls for cables that are wear-resistant, flexible at low temperatures and insensitive to chemicals. Apart from this, the materials employed are required to be halogen-free and recyclable. Thermoplastic polyurethane (TPU) fulfils these requirements in an ideal manner. Thermoplastic polyurethane belongs to the product class of thermoplastic elastomers (T...

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, Highly Filled, Well Dispersed
Highly Filled, Well Dispersed Waxes as Dispersing Agents in Pigment Concentrates Reiner Hess, Augsburg/Germany A precondition for processing pigment concentrates is good dispersion of the pigments. The latest developments use micronised waxes as dispersing agents and give excellent results. Plastics have established themselves in all aspects of daily life in the past decades. They are now available in all conceivable colours. Furthermore, there has been a continued strong trend towards i...

Kunststoffe international, 2005-11-21, Hot Runner Technology Today
Hot Runner Technology Today Systems, Developments, Trends Andreas Lang, Leverkusen/Germany The right hot runner system plays a crucial role in the attainable quality of an injection moulded part. So many different suppliers and systems exist that the application concerned needs to be specified precisely. This survey on new developments and trends casts light on the market and helps to find the right system for a specific application. As plastics parts become more and more complex and are...

Kunststoffe international, 2005-11-21, Hot-runner Technology: Real Wood Applications
Tooling Real Wood Applications Hot-runner Technology. The interior trim strip of an upper middle-range car is manufactured economically and in top quality using a hot-runner system from Incoe International, Inc. In this case, it is not produced by in-mould decoration of a film, but – to give a special touch to the car interior - of a real-wood veneer. Klaus-Dieter Kapp In our society, the automobile is still a status symbol. It is therefore not surprising that some demanding customers for upper ...

Kunststoffe international, 2005-11-21, Injection Moulding Compounders: IMC Technology Opens Up New Fields of Application
Special IMC Technology Opens Up New Fields of Application Injection Moulding Compounders. The combination of injection moulding with continuous plastification offers processing advantages – particularly where it is important to achieve high throughputs, to manufacture products with high filler contents or to solve complex plastification and compounding problems. As a result, injection moulding compounders are venturing more and more into new application fields. Matthias Sieverding Erwin Bürkle...

Kunststoffe international, 2005-11-21, Injection Moulding Simulation: Support for Component Development
Support for Component Development Injection Moulding Simulation. Ever shorter product development cycles require the use of suitable aids to be able to promptly recognise and repair any problems. Particularly for use of special polymers or with complex component geometry simulation can provide crucial assistance during moulded part design. Gerhard Wimmer The history of the development of an injection moulded component can be regarded as three staged and consists of the three legs component de...

Kunststoffe international, 2005-11-21, Injection Moulding Technology for the Packaging Industry (4): Differentiation of Products for Thick and Thin
Injection Moulding Differentiation of Products for Thick and Thin Injection Moulding Technology for the Packaging Industry (4). While the trend towards high-quality, attractively decorated thinwall packagings is continuing, manufacturers of thick-walled packaging solutions are looking for ways of reducing the manufacturing costs of their quality products. The Canadian injection moulding machine manufacturer Husky has efficient solutions for both. Demand for comprehensive in-mould labelling (IML...

Kunststoffe international, 2005-11-21, Injection Moulding Without Gate Marks
Injection Moulding Without Gate Marks Introducing a New System Richard Herbst, Eching/Germany and Friedrich Johannaber, Lohmar/Germany Injection moulders have been dreaming of sprueless injection moulding since injection moulding was first invented. A new valve system, integrated into the runner system, makes side gating of chip cards possible without gate marks. The valve can also undertake the holding-pressure function and separate side or centre sprues without leaving a mark. Injectio...

Kunststoffe international, 2005-11-21, Injection Moulds Direct by Laser
Injection Moulds Direct by Laser New Material for Shortening the Laser-Sintering Process Chain Elke Fritz, Michael Shellabear, Planegg/Germany New products must reach the market faster and faster. Often, the mould construction stage is the stumbling block to market release. Laser-sintered prototype moulds are already shortening development phases considerably. Now, there is a new material available that makes it possible to use laser-sintered moulds for all phases of the product life cycle...

Kunststoffe international, 2005-11-21, Innovations in Extrusion
Innovations in Extrusion Further Developments in Die Technology and in Measuring Systems Heinz Groß, Rossdorf/Germany It is difficult for new process technologies to become established in extrusion technology. A number of the reasons for this are the high line costs, the low number of new lines being installed, the risk of a new technology not giving the desired results after all and the high costs of the tests required on production line. Despite this, new ideas and solutions are repeated...

Kunststoffe international, 2005-11-21, Innovations in Injection Moulding Technology
Innovations in Injection Moulding Technology House Trade Fair at Ferromatik Milacron in Malterdingen/Germany With the slogan "Innovation World", Ferromatik Milacron held its house trade fair in September. A total of 1200 visitors attended the three-day event, 450 of whom were from outside Germany. The trade-fair was accompanied by a series of talks on "innovative injection moulding technologies". In an accompanying talk, Dr. Karlheinz Bourdon, managing director of Ferromati...

Kunststoffe international, 2005-11-21, Interview: Newly Reorganised for the Future
Interview Newly Reorganised for the Future Jos Goessens on the importance of the German automobile market for DSM and plans that the company has for Asia. DSM recently underwent a reorganisation as a global chemical company with life science products and specialties to prepare itself for the future. Kunststoffe plast europe asked Jos Goessens, President DSM Engineering Plastics, what growth potential DSM sees worldwide for engineering plastics. Kunststoffe: What growth in sales does DSM expect...

Kunststoffe international, 2005-11-21, Isocyanate-free Route to Polyurethane
Isocyanate-free Route to Polyurethane Additive for Tailored PU Applications Ton Loontjens and Boudewijn Scholtens, Geleen/Netherlands, Steffen Maier and Rolf Mülhaupt, Freiburg/Germany Carbonylbiscaprolactam (CBC) offers promising potential for plastics processing and polymer diversification. This non-toxic additive converts linear, branched and hyperbranched polyols and polyamines into polyurethanes, polyureas and prepolymers containing blocked isocyanate end groups without either phosgen...

Kunststoffe international, 2005-11-21, Laser Sintering: Rapid Prototyping on its Way to Series Production
Rapid Prototyping Rapid Prototyping on its Way to Series Production Jochen Weidinger Martina Methner Laser Sintering. The term “e-manufacturing” introduced by EOS means fast, flexible and cost-effective production directly from electronic data. Applying this method, parts from each stage of the product lifecycle, from the prototype in product development to individual parts, series parts or even spare parts may be manufactured quickly and economically. Laser sintering has been known as a ra...

Kunststoffe international, 2005-11-21, Logistics Centres For The Polymer Industry
Logistics Centres For The Polymer Industry Michael Baumgärtner, Friedrichshafen/Germany, Wolfgang Krambrock, Weingarten/Germany, Harald Wilms, Houston/USA Production plants for standard plastics are continually growing in size as reactor and extruder capacities become ever larger. Storage, conveying, bagging and shipment capacities for plastics have to keep pace with this development. As an alternative option to outsourcing services, economically operating logistics centres [1] are gaining i...

Kunststoffe international, 2005-11-21, Many Variations
Many Variations The Biaxial Orientation of Expanded Films Martin Wolf, Johannes Sänze and Klaus Stopperka, Siegsdorf/Germany The importance of industrial films is increasing. For holographic and semi-permeable films, foamed films, synthetic papers and blend formulations, growth rates of 15 % and more are forecast. It has now become possible for the first time, using a new process, to biaxially orientate expanded films with functional layers. Biaxially oriented films that can be produced ...

Kunststoffe international, 2005-11-21, Market and Trends: Nanomaterials: Opportunities and Risks
Nanotechnology Nanomaterials: Opportunities and Risks Market and Trends. Nanotechnology represents an attractive link between bioscience and materials science and is a driving force for material innovations in the future. It also presents numerous opportunities for developments in plastics. However, the new nanocomponents must become more affordable and readily available to industry. This trend report points out potential approaches and opportunities. Rolf Mülhaupt Nanotechnology is the key to...

Kunststoffe international, 2005-11-21, Melt Filtration: High-quality Materials from PET Recycling
Recycling High-quality Materials from PET Recycling Melt Filtration. Reprocessing PET bottle flakes into new products places highly stringent requirements on both the material and process engineering. A large number of problems can be solved through the consistent use of melt filters. Ulrich Thiele Stephan Gneuß The extremely rapid growth in the consumption of PET bottles, coupled with improvements in the collection system and changes in European legislation are opening up new possibilities an...

Kunststoffe international, 2005-11-21, Melt Filtration: Making Nonwoven Fabrics from Bottle Flakes
Melt Filtration: Making Nonwoven Fabrics from Bottle Flakes Impurities disrupt melt spinning processes significantly and reduce the lifetime of the spin packs, particularly when processing reclaim material. This contamination can be reliably removed through the use of a fully automatic filtration system. Monika Gneuss The increasing use of polyethylene terephthalate (PET) for bottles and the steadily improving collection system are resulting in a growing supply of PET in the form of bottle...

Kunststoffe international, 2005-11-21, Micro-Injection Moulding: Microfluidic Systems with Integrated Semiconductor Chips
Special Microfluidic Systems with Integrated Semiconductor Chips Micro-Injection Moulding. Combining microfluidic systems and electronic components usually requires a joining process. However, the joints are usually leaky and it is sometimes a problem to integrate the parts. As an alternative, the possibility was investigated of manufacturing a part by injection/insert moulding of the semiconductor chip, and synchronous producing a microfluidic system by micro-injection moulding with the polymer...

Kunststoffe international, 2005-11-21, Model Test Systems: Wear Testing on Plastics processing Machines
Testing Wear Testing on Plastics processing Machines Model Test Systems. Wear on plastics processing machines cannot be simulated. Wear studies are therefore carried out on model test systems. Conventional methods are often time consuming and costly. Two innovative, realistic test apparatuses now permit more precise and time-optimised studies. Roy T. Fox Michael Rudschuck Wear testing methods extend from industrial trials on test rigs with original parts to testing on model systems. Field tests ...

Kunststoffe international, 2005-11-21, Moderate Growth: Polystyrene (PS)
Special: World Market Polystyrene (PS) Moderate Growth. With a global consumption of 11.3 million t in 2003, polystyrene is one of the most important plastics in terms of volume (share of total plastics consumption: approx. 6%). In the past three years, however, demand for this plastic has risen at a below-average rate. Worldwide, consumption is expected to rise by 2.9% a year to reach 13.3 million t by 2008. For polystyrene producers, the last three years have been dominated by consolidati...

Kunststoffe international, 2005-11-21, Mould Technology: Better Performance for Two-Component Technology
Mould Technology: Better Performance for Two-Component Technology A new machine concept extends and simplifies the use of spin stack moulds. The linear arrangement of injection machine units and closing unit improves access to the mould and makes consistent automation concepts possible. By using spin stack technology, injection compression and two-component injection moulding are no longer a contradiction. Dietrich Hunold, Bernd Klotz, Norbert Heyer Different materials are combined into a ...

Kunststoffe international, 2005-11-21, Nanocomposites - En Route to Application
Nanocomposites - En Route to Application Rolf Mülhaupt, Freiburg/Germany, Thomas Engelhardt and Norbert Schall, Moosburg/Germany New families of nanofillers and nanocomposites are opening up unexploited performance potential in plastics, rubber and dispersions. Just small percentages of nanofillers are sufficient to afford major changes of the property profiles of polymeric and effect materials. The range of applications extends from new structural materials through to a variety of functiona...

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, Open-heart Operations
Open-heart Operations All-in Systems and New Combination Systems Compared with “Hot Halves” Kurt Gauler, Rödermark/Germany With the further development of all-in systems and minor design modifications to the mould and hot-runner system, it is now possible for the mould to be configured on the machine in such a way that the complete hot-runner system is exposed when the machine is moved away. This then makes it possible to perform key servicing jobs on an “open-heart” basis, as it were. I...

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, Optimised in 60 Seconds
Optimised in 60 Seconds Computer-aided Design and Optimisation of Co-rotating Twin-screw Extruders Helmut Potente, Karsten Kretschmer, Paderborn/Germany The design of co-rotating twin-screw extruders is frequently based on experience and time-consuming trial and error. Simulation of the process through computer programs such as "Sigma" significantly shortens the time involved and also lowers the costs. The route taken by nearly all polymers leads from the chemical production proc...

Kunststoffe international, 2005-11-21, PET Recycling: Melt Filtration at Constant Pressure
Recycling Melt Filtration at Constant Pressure PET Recycling. Inline compounding of PET bottle flakes on twin-screw extruders is imposing ever greater demands on melt filtration. A newly developed piston-screen changer allows highly effective back-flushing of the filter elements with little pressure fluctuation, even in sensitive applications. Stefan Wöstmann The longstanding trend of substituting PET bottles for glass bottles continues unabated. Consequently, rising amounts of PET recyclate, ...

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, Polyamide: Efficient Pipelining
Plumbing Technology Efficient Pipelining Polyamide. While integration of several functions and assembly steps often yields clear cost benefits for production of component parts, at the same time it places greater demands on development, tooling and the materials employed: an example is found in the development of a heating block that forms the heart of an instantaneous heater. In an all-plastic version it comprises only five parts instead of the previously required eleven individual components. ...

Kunststoffe international, 2005-11-21, Polyaryletherketones (PAEK)
Polyaryletherketones (PAEK) Wolfgang Reimer and Ralf Weidig, Hofheim/Germany Thanks to their versatility, PAEK high-performance polymers are finding use in many areas of industry. Developers and designers are exploiting their good balance of properties to create innovative solutions that meet the ongoing demand for cost reduction combined with optimised functions, weight reduction and extended product lifetimes. Most polyaryletherketones, in terms of volume, are currently produced by Victr...

Kunststoffe international, 2005-11-21, Polycarbonate instead of Glass: Large Car Windows from an Injection Moulding Machine
Injection Moulding Large Car Windows from an Injection Moulding Machine Polycarbonate instead of Glass. Injection compression offers designers design freedom for automobile windows and the technical variety of the world of plastics. A new moulding technique from Engel called "Glazemelt" provides the necessary process reliability. Advances in automaking are undoubtedly coupled with the continually increasing amount of modern plastics in automobiles. Replacement of glass in windows with...

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, Polymethyl Methacrylate (PMMA)
Polymethyl Methacrylate (PMMA) Klaus Albrecht, Rudolf Blass, Matthias Schäfer and Michael Träxler, Darmstadt/Germany Because of its typical properties such as surface hardness, transparency, brilliance, outstanding colourability as well as ideal weather resistance, PMMA has not been replaced by other materials in any of its major fields of application. It is mainly employed in three sectors: the automotive and construction industry as well as signage and lighting. The concentration of comp...

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, Polypropylene - An Alternative?
Polypropylene - An Alternative? Window Profile Material in PP Compound Egon Brenner, Linz/Austria PP window profiles are being tested by way of an alternative to other window materials. The experience acquired with polypropylene windows to date, together with their high innovation potential and good price-to-performance ratio has prompted hopes that PP will emerge as the prime alternative to other materials. Polypropylene (PP) has been produced on an industrial scale since 1957. Intensiv...

Kunststoffe international, 2005-11-21, Polypropylene-Cellulose Compounds
Polypropylene-Cellulose Compounds High Strength Cellulose Fibres Strengthen Injection Moulded Parts Peter Weigel, Johannes Ganster and Hans-Peter Fink, Potsdam-Golm/ Germany, Jochen Gassan, Nentershausen-Dens/Germany, and Kurt Uihlein, Obernburg/Germany Under certain conditions high strength cellulose fibres can replace glass fibres as reinforcing materials for polypropylene. They have weight, abrasiveness, recyclability and disposal advantages. Presently there is an intensive search for...

Kunststoffe international, 2005-11-21, Polystyrene (PS)
Polystyrene (PS) Daniel Wagner, Ludwigshafen/Germany With a world-wide consumption of 10.5 million tonnes in 2001 polystyrene is counted amongst the quantitatively most important thermoplastics and continues to be ranked in fourth place after PE, PP and PVC. Also in recent years on the average the dynamic development of consumption was a little greater than that of the gross domestic products of the corresponding countries and it is generally expected that this development will continue. Gen...

Kunststoffe international, 2005-11-21, Polyurethane Processing: Screw Spindle Pumps with Magnetic Coupling
PU Technology Screw Spindle Pumps with Magnetic Coupling Polyurethane Processing. Magnetic couplings can overcome the restrictions that otherwise apply to mechanical seals in screw pumps. A contactless rotational transmission causes no wear and tear, thus guaranteeing consistent quality from that side. Screw spindle pumps, which function by the positive displacement principle, have been tested and proven over a long period of time. For this reason, they are traditionally used for conveying lu...

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, Printing Plastic Surfaces Precisely and Economically
Printing Plastic Surfaces Precisely and Economically Max Dominik, Eschwege/Germany Following the manufacture of a plastic product, it is often necessary to treat its surface by painting, embossing, polishing or printing for the purposes of decoration or identification, in order to make it saleable or useful in the application. Though there are unlikely to be any surprising innovations in these technologies, ongoing improvements, rationalisation and automation of the processes and systems can...

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 Optimisation: Running Smoothly
Process Optimisation: Running Smoothly Materials with properties tailored to a final product are often more difficult to process. When plastication using standard component reaches its limits, the machine manufacturer’s special expertise is called for. Following detailed studies into the processing of self-lubricating polymers, a new plastication unit design was conceived. Christian Gornik, Harald Bleier In “tribo materials”, the lubricant and material are combined, by means of special add...

Kunststoffe international, 2005-11-21, Production Control: Press Process Transparency
Production Control: Press Process Transparency On over 30 presses, the Aircabin GmbH moulds a great variety of fibreglass components for the interior furnishings of the Airbus fleet. For increased transparency, reliability and efficiency down the entire production line, a central PC-based HMI system has been in use for about one year. Jürgen Speck The company founded in 1960 as Bölkow Apparatebau Nabern – later also a division of MBB and Deutsche Aerospace Airbus – has established itself a...

Kunststoffe international, 2005-11-21, PUR Composite Spray Moulding (PUR-CSM): Open to Many Different Applications
PUR Processing Open to Many Different Applications PUR Composite Spray Moulding (PUR-CSM). A new system variant of polyurethane spray technology involves the use of an isocyanate plus a fast- and a slow-reacting polyol. Depending on requirements, various additives, such as colour components, blowing agents or chopped reinforcing fibres, can be incorporated. For the production of moulded parts, only one mould half is required and no mould carrier. Ingo Kleba Thomas Kirsten In processing a rea...

Kunststoffe international, 2005-11-21, Quality assurance: Additives – a Book with Seven Seals?
Quality assurance: Additives – a Book with Seven Seals? As invisible aids additives ensure that plastic parts can be produced in the right quality and also that their quality is retained during the intended use period. Revealed quality deficiencies frequently suggest the use of inappropriate additivation, which can be detected through analysis. Matthias C. Hund, Friedhelm Gores Plastics contain a number of ingredients that are added to obtain the desired product properties. In contrast to ...

Kunststoffe international, 2005-11-21, Quality Assurance: Comparison of Thermal Stability Measurement Processes for PVC
Quality Assurance: Comparison of Thermal Stability Measurement Processes for PVC Thermal stability is one of the most important criteria for the processing and application of PVC. There are four different methods used to measure it. An interlaboratory test was carried out to compare different test equipment and their precision using systematically determined data. A simple method of determining the thermal stability of polyvinylchloride (PVC) is to measure the amount of hydrogen chloride evo...

Kunststoffe international, 2005-11-21, Railroad Rolling Stock: On Track with Lightweight Construction Techniques
Transportation On Track with Lightweight Construction Techniques Railroad Rolling Stock. Plastics make trains lighter, are economically producible and can fit the many special requirements on rolling stock construction. Also individual parts can be manufactured economically with modern production technologies. Since many functions can be integrated in fibre reinforced composite materials, they meet requirements on a high degree of modularity. Eva Bittmann The size of the world-wide railway tec...

Kunststoffe international, 2005-11-21, Retrospective: The Development of Injection Moulding
Special The Development of Injection Moulding Friedrich Johannaber Retrospective. For many years, the development of injection moulding has paralleled the development of polymers. The basic technology for today’s highly complex and fully automatic production machines traces its origin back to 1872. Bock divides the history of injection moulding into five eras [1]. This division is retained here with some additions, so that the attentive observer of this branch of industry can follow very eas...

Kunststoffe international, 2005-11-21, Safe Braking
Safe Braking ABS Accumulator Pistons in PPS for Automotive Engineering Uwe Behle, Frankfurt am Main/Germany A further-refined PPS is once again displaying its potential for fulfilling extremely demanding automotive applications with the example of the chemical, pressure and heat-resistant accumulator pistons employed in the ABS brake systems produced by Bosch. Use is made of a material grade containing 65% glass fibre and mineral filler. The precision parts are produced in 8-cavity hot-run...

Kunststoffe international, 2005-11-21, Screw Pumps with Magnetic Couplings: Conveying Polymer Components
Auxiliaries Conveying Polymer Components Screw Pumps with Magnetic Couplings. Power transmission via non-contact magnetic couplings has undergone comparatively tumultuous growth over the last two decades. The article shows how, as these coupling systems increasingly become established, they can be used to exploit the optimisation potential in screw pumps. Christoph Schneider In conventional designs, the pumps are connected directly to the drive by means of a mechanical coupling (Fig.1). The p...

Kunststoffe international, 2005-11-21, Sealing under Extreme Conditions
Sealing under Extreme Conditions PEEK for Gaskets and Seals in Automotive Construction Ralf Weidig, Hofheim/Germany Productivity increases, technological progress and the high cost awareness in the automotive industry are placing ever higher demands on the gaskets and seals used there. In automotive transmissions, engines and steering, the high-temperature material polyetheretherketone (PEEK) provides an attractive range of properties. Seals and gaskets have always been of central import...

Kunststoffe international, 2005-11-21, Self-insulating Hot-runner with Needle Valves
Self-insulating Hot-runner with Needle Valves Solution for Production of the ABS Back Wall of an Alarm Clock, with a 4-Cavity Hot-runner Mould Edmund Lindner, Kassel/Germany, and Kurt P. Cuttat, Givrins/Switzerland Insulated manifolds have been in use for some time. They can be selectively adapted for processing most thermoplastics. Colour and material changes in closed-system hot-runner manifold blocks are difficult and time consuming. Many plastic melts have the unwelcome property of s...

Kunststoffe international, 2005-11-21, Shear Punching of Thermoplastic Film
Shear Punching of Thermoplastic Film Comparison of Different Films and Punch Parameters Olaf Jacobs, Heiner Demenus, Klaus-Peter Wolf-Regett, Walter Dalock, Lübeck/Germany With the thermoforming/punching process, the larger the number of cavities the greater the economic benefit. On the other hand, the cutting length and thus the punching force also increase significantly. A study of the punching forces therefore has a decisive influence on profitability calculations. With the aid of the...

Kunststoffe international, 2005-11-21, Shortened Product Cycles: The Changing Face of Extrusion Technology
Shortened Product Cycles: The Changing Face of Extrusion Technology Extrusion technology is increasingly characterised by the fact that processors are demanding high-performance systems on the one hand and universal applicability on the other. High-performance systems, which can also be used in a broad range of applications, would seem to be uniting these two requirement profiles. Johannes Wortberg, Dirk Kaczmarek, Carsten Gross In a development that is affecting all the different producti...

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, 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, Styrene Copolymers: Both Tough and Transparent
Packaging Both Tough and Transparent Styrene Copolymers. Interest in transparent materials is growing and demand for crystal-clear, brilliant products is exceptionally high. An important application segment for these materials is food packaging. Styrene-butadiene (SBS) block copolymers have been established in this market for 20 years. Nevertheless, they still have potential for innovation and can be continually improved. Daniel Wagner A combination of high transparency and brilliance with goo...

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 Properties: Modification of Polyamides
Engineering Plastics Modification of Polyamides Tailor-made Properties. With new long-chain dicarboxylic acids, it is possible to specifically influence the process temperatures, process cycles and mechanical and chemical properties of polyamides. They can also exert an effect on the appearance of these engineering plastics. Thorsten Roloff Ulrich Nagorny Ulrike Erkens The properties of engineering plastics can be customised through the selective synthesis of polymer building blocks. In this...

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, Thermoforming: Packaging is Dominant
PE103118 Trade Fair Report Packaging is Dominant Thermoforming. After the technical parts sector saw significant growth three years ago, the packaging sector was more strongly represented at K2004. In addition to known technologies, interesting innovations were presented in detail. With the KMD 85 type automatic pressure formers, Kiefel AG, Freilassing/Germany, presented a machine for mass production of packaging parts. Its drive directly incorporates the new “Simotion” control technology from S...

Kunststoffe international, 2005-11-21, TPE Test for Automotive Engineering
TPE Test for Automotive Engineering Comparison of TPE with Elastomers Norbert Vennemann, Osnabrück/Germany, Susanne Leifheit and Peter Schulz, Wolfsburg/Germany This paper compares selected thermoplastic elastomers in respect of key mechanical properties, ageing behaviour and oil resistance with two covalently crosslinked elastomers based on EPDM and ECO. A new evaluation method also makes it possible to establish specific differences between the TPEs. Thermoplastic elastomers (TPEs) hav...

Kunststoffe international, 2005-11-21, Trends in Bio-materials: The Signs are Set for Growth
Biodegradable Polymers The Signs are Set for Growth Trends in Bio-materials. Progress is being made in the market – there is no shorter way of summarising the current situation as regards the launch of biodegradable materials in Europe. Within political circles too, this innovation is finding growing support. This sector report focuses on trends in the European market and progress made in shaping the framework conditions. Harald Käb Innovations are the basis of lasting successful business – the...

Kunststoffe international, 2005-11-21, Trends in Flat Film Extrusion
Trends in Flat Film Extrusion New Developments in Control Technology and Special Applications Frank van Lück, Aachen/Germany Strong growth in the plastics industry is also profiting manufacturers of flat-film extrusion lines, as evidenced by their increased R&D activities. Besides eye-catching developments such as "modular systems" and "increased output", other trends include improvements in control technology and adaptation of flat-film lines to special applications, and t...

Kunststoffe international, 2005-11-21, Trends in Plastic Furniture: Designing with Plastic
Trends in Plastic Furniture: Designing with Plastic Back in the sixties, furniture designers eagerly seized on plastic as a symbol of the trendy way of life. They also used it as a provocation against traditional materials like wood. In later years, consumers lost interest in such designs. At this year’s furniture fair in Milan, it was evident that all the big designers had been working with plastic. Are plastics experiencing a new lease of life in furniture design? Gudrun Klein In the six...

Kunststoffe international, 2005-11-21, Triple Combination
Triple Combination Multi-component Injection Moulding of Thermoplastics, Elastomers and Thermosets Richard Herbst, Eching/Germany, and Friedrich Johannaber, Lohmar/Germany Special conditions will have to be met, if different plastics are to be combined by injection moulding. The latest processing technology employs stack moulds and handling units, for increasing profitability through high output rates from relatively small machines. Gripping and handling systems, combined with magazining f...

Kunststoffe international, 2005-11-21, Turning Stack-Mould Technology Marks a Quantum Leap Forward
Turning Stack-Mould Technology Marks a Quantum Leap Forward A Symbiosis of Innovative Injection Moulding and Mould Technologies Rainer Armbruster, Haslach/Germany, and Jörg Dassow, Malterdingen/Germany When parts are produced by the multicomponent technology, the semi-finished injection mouldings are generally transported on a rotary table. The turning stack-mould technology that was presented some time ago and has now been fully developed is superior to the rotary-table method in terms of...

Kunststoffe international, 2005-11-21, Vacuum Pumps for Extruder Degassing
Vacuum Pumps for Extruder Degassing Fields of Application and Design Principles Mark Redmann, Maulburg/Germany For a reliable extrusion process, it is essential to choose the right degassing pump technology. If the wrong pump type is used, the final product may not fall within quality specifications. In an extreme case, serious disruption of the production process may result. In many industrial fields vacuum has developed from a process aid to a process parameter. Apart from its use for ...

Kunststoffe international, 2005-11-21, Vehicle Acoustics: Reducing Noise Development in Vehicles
Automotive Reducing Noise Development in Vehicles Vehicle Acoustics. The design and choice of material have a major influence on the acoustic properties of parts. The acoustic evaluation of materials and parts requires a comprehensive measuring and testing setup. These help to selectively develop plastics and also complete modules for the automotive industry that have the desired good acoustic properties. Axel Zschau Kai Becker Richard Bourdon The opimisation of acoustic properties used to b...

Kunststoffe international, 2005-11-21, Weather-resistant TPE
Weather-resistant TPE Specially-stabilized TPW Based on SBC Gerhard Berger and Markus Beitzel, Waldkraiburg/Germany TPE parts for outdoor applications are gaining increasing significance. This is creating a need for materials to fulfil the extreme requirements. Employing a new generation of styrene block copolymers (SBC) with an improved stabilization system, it is now possible to withstand outdoor simulation periods of several years. Steadily increasing quality demands on the part of OE...

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 Barrier Screws Can Achieve
What Barrier Screws Can Achieve Comparison of Different Screw Designs for Injection Moulding Polyolefins Sabine Pahlke, Dieter Schimmel, Christoph Mehler and Ansgar Jaeger, Schwaig/Germany Plasticizing systems with standard screws continue to cover a very wide range of applications in injection moulding. Nevertheless, in melting engineering plastics or for high outputs with polyolefins, they still come up against their limits. For such cases, special screws and high performance screws are ...

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, Worldwide Stable Growth: Polyurethanes (PUR)
Trend Report Crosslinking Plastics Polyurethanes (PUR) Worldwide Stable Growth. The market for polyurethanes is showing steady growth worldwide, currently at an average annual rate of about 5%. This growth results partly from increasing demand for raw materials for known applications, but particularly from innovations in raw materials and processing, and new potential applications. Frank Bertram In 2004, total world consumption of polyurethanes was about 10.8 million tonnes (Fig.1). The marke...

Kunststoffe international, 2005-11-30, Fluoro Polymers: Safe Construction of Chemical Apparatus and Plant
Elastomers Safe Construction of Chemical Apparatus and Plant Fluoro Polymers. Constantly rising demands on chemical apparatus, pipelines and plant increasingly necessitate the use of high-performance materials. Fluoro polymers are finding growing application in self-supporting constructions, e.g. containers and feed devices, and in linings for protecting containers, towers and pipelines against corrosion. Klaus Hackel The – in the classical sense – thermoplastic fluoro polymers PVDF (polyvin...

Kunststoffe international, 2005-11-30, Transparent PP Bottles: In the Overtaking Lane
Commodity Plastics In the Overtaking Lane Transparent PP Bottles. Glass-clear polypropylene (PP) is no longer a distant dream. A combination of new materials with improvements in the stretch and injection stretch blow moulding processes (SBM/ISBM) means that PP is now competing directly with PET in some segments. But PP also offers many advantages in conventional blow moulding (EBM), with transparency and heat resistance being among the most important. Markus Gahleitner Max Wachholder Over the...

Kunststoffe international, 2005-12-08, A Status Report (1): Versatility for Mass Production in MuCell Injection Moulding
Injection Moulding Versatility for Mass Production in MuCell Injection Moulding A Status Report (1). The injection moulding of physically foamed plastic parts with a microcellular foam structure (“MuCell”) has found its feet. In the first part of this series of articles, this is demonstrated using the example of Engel technology, with state of the art plant technology and process control, and the growing number of applications and process combinations. The injection moulding of foamed parts by ...

Kunststoffe international, 2006-01-09, PTFE-polyamide Materials: Service Life Trebled
Composite Material Service Life Trebled PTFE-polyamide Materials. Chemically coupled PTFE-polyamide compounds (PTFE-PA) are a new group of materials with advantageous properties for tribological applications. Because of the strong bond between the two polymers and the resulting high wear resistance, components produced from these materials have a longer service life than components produced from conventional compounds with a similar structure. Dieter Lehmann The development of chemically couple...

Kunststoffe international, 2006-01-15, Mouldmaking Technology at Fakuma und EuroMold: Engineering Lights Comes Out from Under the Bushel
Tooling Engineering Lights Comes Out from Under the Bushel Mouldmaking Technology at Fakuma und EuroMold. “Cautious optimism” describes the mood among injection mouldmakers, even if it is sometimes difficult to discern. What is clear, however, is an expansion of competency: while the majority was previously involved largely in machining activities, mouldmakers today provide project management and offer a comprehensive range of services. And they are not hiding their engineering light under the ...

Kunststoffe international, 2006-01-15, State-of-the-Art and Perspectives: Laser Beam Processing of Polymers
Laser Laser Beam Processing of Polymers State-of-the-Art and Perspectives. From creating nanostructures on surfaces to assembling large lightweight parts, laser beams find use as flexible tools in polymer part manufacturing – new processing techniques that employ highly functional polymers are expanding the field of application for laser technology continually. Arnold Gillner With the possibilities it offers for welding, cutting and modification, the laser technology available today covers a...

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, 2006-02-23, 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, 2006-03-07, Mass Production: Unlocking the Foaming Process
Foam Injection Moulding. Unlocking the Foaming Process. Mass Production. Shortening the injection moulding cycle time and reducing the weight and warpage of the end product are worthwhile goals for the processor. It requires no more than to foam the plastic melt by feeding a blowing agent. Only shortly after the introduction of the Optifoam process, a supplier to the automotive industry has now implemented the first example of mass production with a technically challenging application. In close...

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, Roller Rail System: Heavy Traffic on the Injection Moulding Machine
Special Heavy Traffic on the Injection Moulding Machine Roller Rail System. A new generation of large swivel-platen injection moulding machines produce automotive window panes by injection-compression moulding. Special heavy-duty roller rail systems guide the up to 30 tonnes weight reliably and precisely. Werner Jaris Jochen Mitzler Larger, more precise, more complex: just as in sport, in plastics processing, too, the bar is continually being raised. A major driving force is the automotive indu...

Kunststoffe international, 2006-05-23, Application Solutions: Nanoproducts Highly Praised – But What Are the Benefits?
Special Nanoproducts Highly Praised – But What Are the Benefits? Application Solutions. The importance of nanomaterials in science and industry is steadily increasing. Through their influence on polymer structures, they make it possible to obtain new, previously unknown properties and surprising solutions. The survey shows some practical examples of the relationships between the structure and properties of polymers in familiar applications. Franz Brandstetter “Nano” is the word on everyone’s l...

Kunststoffe international, 2006-05-23, Transparent Nanocomposites and Hybrid Materials: Invisible Helpers
Special. Invisible Helpers. Transparent Nanocomposites and Hybrid Materials. There would seem to be no limit to the variety of functional fillers. Inorganic nanoparticles can suitably be used for functionalising transparent plastics, since their small dimensions mean they are not visible to the human eye, yet they still bring completely new functions with them. Stefan Kaskel. Inorganic fillers have traditionally played a decisive role in adjusting the mechanical properties of polymers, suc...

Kunststoffe international, 2006-06-29, Quality Planning: From Customer Requirement to Industrial Mass Production
Quality Assurance From Customer Requirement to Industrial Mass Production Quality Planning. The term quality planning describes a method for improving the cost efficiency of the production process and enhance customer satisfaction. By taking suitable measures, a company aims to fulfil both the various market requirements and the requirement profile of the particular application. Gerhard Berger Markus Beitzel In accordance with the quality planning method, Kraiburg TPE GmbH, Waldkraiburg follo...

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, 2006-09-05, Maintenance Software: From the Pilot to the Standard
Market and Management From the Pilot to the Standard Maintenance Software. The more complex a company’s products and processes, the more important structured maintenance becomes. But good facility and maintenance management (FMM) software is rare. Therefore, a software specialist worked together with an injection mould-ing machine manufacturer on a pilot project to develop a new FMM sys-tem, which is now to be launched on the market. Ralf Haassengier About ten years ago, the injection moulding...

Kunststoffe international, 2006-09-08, Injector Technology for Water Assist: The Key to Success
Injection Moulding The Key to Success Injector Technology for Water Assist. In many cases the success or failure of a water-assisted injection moulding technology (WIT) application depends on the injector technology. The injector must introduce the water volume required to form the part-cavity into the molten polymer core in a controlled and leak-tight way. The Institute of Plastics Processing (IKV) has investigated different designs of known injectors for their suitability and developed and te...

Kunststoffe international, 2006-09-18, PU Machine Engineering: Room for Foam
Trade Fair Report Room for Foam PU Machine Engineering. Plug-and-play was one of the buzzwords in PU processing machines. For all big machine suppliers, the trend is moving quite clearly in the direction of compact, modular-designed metering machines that can be started up without any major installation work. In the field of mould conveyor systems, the former rigid systems are gradually being replaced by flexible systems that allow the moulds to be changed over while production is still running...

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, Profile and Pipe Extrusion: Precise, Flexible and Fast
Extrusion Precise, Flexible and Fast Profile and Pipe Extrusion. As products become more complex, batch sizes smaller and price pressure increases, new technical solutions must be found to improve the cost effectiveness of extrusion lines. Developments are focusing on achieving flexible production workflows, shorter tooling times and higher plant productivity. Johannes Wortberg Paul Gorczyca The large variety of products and desire to keep stocks low and produce “just in time” are leading to ...

Kunststoffe international, 2006-09-28, A Personal Opinion: Has Injection Moulding been Fully Exhausted?
Injection Moulding Has Injection Moulding been Fully Exhausted? A Personal Opinion. So the technical possibilities in injection moulding machine construction have been exhausted? If such arguments had ever been valid, we would still be driving at 20mph on our roads and a journey to China would take three months. Helmar Franz If we review the development of injection moulding machine manufacturing over recent years, we could join in with the hymn of praise about the innovations that are taking p...

Kunststoffe international, 2006-09-28, Reactive Processing: From Expanded Foam to Structural Part
PU Technology. From Expanded Foam to Structural Part. Reactive Processing. Developments here are characterised by simplification of the machinery and user-friendly ease of operation. In addition there is increased flexibility and specialisation in production plants. By combining different processes specific to the customer new product ideas are achievable. Two interesting technologies take the form of spray technology for heavy layers and spray impregnation of semi-finished fibre-reinforced pro...

Kunststoffe international, 2006-09-28, Screen Changers: Economic Aspects of Melt Filtration
Filtration Economic Aspects of Melt Filtration Screen Changers. Filtration systems have a large influence on the cost efficiency of production. There are a large number of factors that determine which filtration system is most appropriate for a particular process. Stephan Gneuss When selecting the right melt filtration system for an extrusion line, two questions are paramount: firstly, which filtration system is necessary to ensure the quality of the final product; secondly, which filtration ...

Kunststoffe international, 2006-09-28, Wall Thickness Control: Adjustable Flow-channel Geometries – the Future in Extrusion Die Making?
Extrusion Adjustable Flow-channel Geometries – the Future in Extrusion Die Making? Wall Thickness Control. The wall thickness of extruded products can be controlled by influencing the local flow resistances in the die flow channel. Advances in extrusion die making now permit thickness control of pipes, sheets and even coextruded layers. Heinz Gross Extrusion dies with flexible flow-channel walls permit fine tuning of the melt-flow distribution within a tool while production is running. A compl...

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, 2006-10-27, Practical Example: 16-Cavity Hot-Runner Mould for Medical Packaging Parts
Tooling 16-Cavity Hot-Runner Mould for Medical Packaging Parts Practical Example. The article describes the layout of an injection mould for medical packaging parts, and how the engineering details were used to solve the expected problems. The tubular medicinal packaging parts are internally threaded on both sides separately and divided in the middle by a thin wall. They are produced from an easily flowing polypropylene known for being ropy. To keep this effect from causing problems in p...

Kunststoffe international, 2006-11-04, Enhanced Productivity through Retrofits: Communication Boosts Business
Injection Moulding. Communication Boosts Business. Jörn Krimpenfort, Enhanced Productivity through Retrofits. Ageing injection moulding machines can only be modernised for a high outlay, since the requirements placed on the machine's control system are constantly rising. A new retrofit concept allows older machines to be brought up-to-date and integrated in existing IT concepts at a low cost. One of the world's leading suppliers of automation solutions, Phoenix Contact GmbH & Co. KG u...

Kunststoffe international, 2006-11-24, Additive Systems: Composition Decides
Compounds. Composition Decides. Eric Richter. Additive Systems. In fibrous wood-plastic composites (WPC), interaction between the individual components wood, plastic and additive is optimal. A variety of wishes posed even by “wood lovers” to such a material can thus be complied with. There is a potential for application in exterior house panelling, terrace and veranda floors, fence systems and handrails as well as window systems. Wood is one of the major renewable resources and, still today, is...

Kunststoffe international, 2006-12-06, Compounding Technology: Striving for Technology Leadership
Market and Management Striving for Technology Leadership Compounding Technology. Around 120 participants attended a two-day workshop at Leistritz Extrusionstechnik GmbH, Nuremberg/Germany, to learn about manufacturing specialty compounds. The main topics were “production of nanocomposites”, “foaming of a biodegradable polymer” and “production of a TPE-V compound”. After presentations, demonstrations were carried out in the pilot plant. The talks were given by acknowledged experts, such as Pro...

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, 2007-03-15, Duo Lamination for Multiple Decors
Duo Lamination for Multiple Decors Cost-Effective Process Integration An innovative process for manufacturing car interior trims with multiple decors offers three advantages: the greater production integration reduces production costs; the use of adhesives is completely eliminated, and product quality is improved because of the shorter tolerance chain. Georg Kaufmann, Yann Buchet For many years, Georg Kaufmann Formenbau AG, Busslingen/Switzerland has pioneered the construction of moulds fo...

Kunststoffe international, 2007-04-17, Forming and Assembly in One Process
Forming and Assembly in One Process Assembly Injection Moulding Through choice of the combination of materials, the geometry of the part to be made and the injection moulding parameters the properties of the joints produced in assembly injection moulding can be selectively set: integral, form-fitting or frictional or mobile and flexible. Current research work shows the relationship between the boundary conditions of the process and the properties of the joint. Ernst Schmachtenberg, Marcus Sch...

Kunststoffe international, 2007-05-14, Customised Property Combinations
Customised Property Combinations Polypropylene Films Air-quenched blown film was solely a domain of polyethylene until a few years ago. With the polypropylene grades that have since been introduced into this area of processing technology, the application and property spectrum of films produced by this method has considerably widened. New product developments in the area of random and heterophase copolymers are taking account of this trend and permitting economic solutions in the packaging sec...

Kunststoffe international, 2007-05-14, Precise and Flexible - Layer for Layer
Precise and Flexible - Layer for Layer Complete Cast Film Lines The demand for high-quality cast films requires smart line concepts for a wide range of applications. They include barrier films, metallisable films, laminating films and stretch films. A new generation of production lines manufactures CPP films at a rate of more than 300m/min and PE films at up to 550m/min. Michael Beckhoff Helmut Meyer The newly designed coextrusion cast film lines can produce composite films of up to nine...

Kunststoffe international, 2007-06-18, Melt Filters in Foam Extrusion
Melt Filters in Foam Extrusion Expanded Foam Sheet Production By using filter systems plant downtimes caused by impurities and contaminants in expanded foam sheet production can be reliably prevented. In doing so the procedure for changing filter systems ensures that the pressure-sensitive process for producing expanded foam cannot be disrupted. Oliver Schmidt Panels made from extruded polystyrene foam are frequently employed for insulation purposes in the building industry on account of ...

Kunststoffe international, 2007-07-18, Cooling without Regret
Cooling without Regret Water Treatment Technically demanding plastic parts and mass-produced articles have one thing in common in production: the efficiency of cooling the injection mold and the hydraulic components directly affects the quality of the molding and the economic efficiency of the process. When renovating their cooling installations many companies discover previously hidden potential savings. Nico Küls A particular characteristic of progressive companies is that they also contin...

Kunststoffe international, 2007-07-18, Potential for Increased Performance
Potential for Increased Performance Customized Materials Different blends or compounds based on polypropylene can have the property potential of engineering plastics. Newly developed blend families were suitably modified to improve their wear behavior and impact strength. Roman Reder In the polyolefins sector, compounds or blends can be produced as customized materials by mixing with fillers, additives or other polymers. These can offer higher performance than the matrix polymer. On the bas...

Kunststoffe international, 2007-07-18, Yesterday’s Surfaces for Tomorrow’s Applications
Yesterday’s Surfaces for Tomorrow’s Applications Technical Premiere Unfortunately, traditional materials like metal and wood have certain undesirable properties such as high weight or moisture-susceptible surfaces. During the 3rd Technology Day held at Kunststoff Helmbrechts AG, a manufacturing process celebrated its premiere, with which the appealing look and texture of these materials can be transferred to plastic components. Andreas Stein On April 19th, some 130 visitors found their way t...

Kunststoffe international, 2007-08-14, A Route to Cost-effective Photovoltaic Technology
A Route to Cost-effective Photovoltaic Technology Polymer Solar Cells The most recent branch of photovoltaics research involves polymer solar cells based on organic conjugated functional polymers. With semiconductor layer thicknesses around one-thousandth the thickness of a human hair, these polymer solar cells represent the thinnest of all thin-layer technologies. With their comparatively low investment and production costs, they are highly attractive. Steffi Sensfuss et al. Photovoltai...

Kunststoffe international, 2007-08-14, Focus on Attractive Added Value
Focus on Attractive Added Value BASF The company BASF is going to concentrate increasingly on global business that promises a high margin. Accordingly, it would like to increase the percentage of sales related to innovative products and specialties for individual sectors and customers from about 25 to over 40 %. The company made this announcement at its pre-K 2007 press conference. Plastics are energy-efficient materials and for this reason alone will continue to be in great demand. With t...

Kunststoffe international, 2007-08-14, New Structure Bears Fruit
New Structure Bears Fruit Market-oriented Reifenhäuser presented its new stucture. The builder of machines and systems based in Troisdorf, Germany, has turned its autonomous production units into a pool of small and flexible corporations. Strategic services will become the responsibility of the main holding company. At a pre-K2007 press conference, the management of the Reifenhäuser Group stated that their restructuring, begun in May 2005 and completed in July 2006, can now be considered a...

Kunststoffe international, 2007-08-14, Output under Pressure
Output under Pressure Pipe Extrusion Standard raw materials for the production of pipes undergo continuous improvements, whereby the processor makes use of additives to adapt them to his needs. In their role as solution providers, and to keep abreast of technical advances, machine builders are forced to push the development of high-performance extruders. Walter Häder For the manufacture of polyolefin pipes, mainly single-screw extruders with grooved feed zone are used. When viewing the de...

Kunststoffe international, 2007-08-14, Positive Response from Customers
"Positive Response from Customers" At the pre-press conference for K 2007, DuPont also introduced its sustainability goals for the period up to 2015. On the fringes of the event, Gudrun Klein, who is responsible for covering materials and applications at Kunststoffe magazine, spoke to Nandan Rao, Technology Director at DuPont Performance Materials, about current developments in bioplastics and their implementation in the market. Kunststoffe: Which plastics based on sustainable raw ma...

Kunststoffe international, 2007-08-14, Sophisticated, Robust, Resource-Saving
Sophisticated, Robust, Resource-Saving High-tech Toys Gone are the days when toys were simple, injection molded articles made from cheap bulk plastics. Today’s toys are made from high-grade polymers in no way inferior to materials used for building cars or in medical technology. Some of them are processed in special techniques, such as sandwich or structural injection molding. The processing methods also satisfy highest standards – flash, sinkholes, weld lines or trapped air are nowhere to b...

Kunststoffe international, 2007-08-14, Tiny Tubes with a Huge Impact
Tiny Tubes with a Huge Impact Carbon Nanotubes The unusual properties of carbon nanotubes have raised high hopes in nanotechnology and material science. A new efficient synthesis process has now cleared the way for industrial applications and commercial use already includes increasing the strength of plastic components and the production of conducting thermoplastic compounds. Martin Schmid A central building block for success at Bayer MaterialScience, Leverkusen, Germany, is innovation. ...

Kunststoffe international, 2007-09-19, Cost Effectiveness as Incentive
Cost Effectiveness as Incentive Film and Sheet (Trade-fair-pre-report K 2007) Most of the film and sheet produced worldwide falls into the category of commodity products. Even though the layer structure and the process and machine technology required for manufacturing have become anything but trivial in most products, the margins that can be obtained are nevertheless low for the processors. It’s no surprise, then, that machine manufacturers are focusing on the catchword "cost effectivene...

Kunststoffe international, 2007-09-19, Flexible with High Loadbearing Capacity
Flexible with High Loadbearing Capacity Elastomers (Trade-fair-pre-report K 2007) Thermoplastic elastomers and technical elastomers are used mainly for special applications in automotive engineering, the sports and leisure sector or the chemical industry. Depending on their chemical structure, they provide cushioning and high-performance properties. In many cases, high safety or the required comfort can only be achieved by using these materials. At K2007, individual manufacturers will provid...

Kunststoffe international, 2007-09-19, Mastering Demanding Challenges
Mastering Demanding Challenges Commodity Plastics (Trade-fair-pre-report K 2007) With customized polyolefins – sometimes without additives – it is possible to employ commodity plastics in sectors previously reserved for other resins. The opportunity for savings with a simultaneous improvement in properties attracts customers. The global demand for plastics since 1990 has grown, on average, 5.5 % per year – and this trend is expected to continue at an annual growth of about 5 % until 2015....

Kunststoffe international, 2007-09-19, Polycarbonate Automotive Glazing
Polycarbonate Automotive Glazing Vast Substitution Potential Automotive glazing has been a topic of conversation in the plastics industry for a long time. In the interim some vehicles have been equipped with panes or transparent elements made from plastic, but these are still only niche applications. However, in the last ten years machinery and tooling technology has reached a stage where the ability to go into mass production is regarded as proven. Jochen Zwiesele Franz Summerer With 3....

Kunststoffe international, 2007-09-19, Several Irons in the Fire
Several Irons in the Fire Molds, Hot-Runners, and More (Trade-fair-pre-report K 2007) Without a new injection mold, there can be no new molding. But Europe’s mold makers are faced with ever-increasing cost pressure and competition. This requires intelligent solutions, both from the mold makers themselves and from the component and assembly manufacturers who specialize in mold technology. The exhibitors’ program for this year’s K trade show demonstrates how this can be done. For cost-effect...

Kunststoffe international, 2007-09-19, Technology Barometer Indicates Fair Weather
Technology Barometer Indicates Fair Weather Process and Applications Technology (Trade-fair-pre-report K 2007) Now that economic indicators have been showing positive signals for some time, injection molders may once again benefit from technologically interesting developments. Machinery manufacturers have, on the one hand, succeeded in combining known technologies in novel ways and, on the other, also gone in completely new directions. It is precisely by combining known injection molding t...

Kunststoffe international, 2007-10-21, Four Ways towards a Multi-Component Bottle Crate
Four Ways towards a Multi-Component Bottle Crate Moldmaking Crates have undergone radical changes in recent years. The humble, often awkward-to-carry crate of old has been transformed into a multifunctional design object that is easy to carry and is increasingly being used as a marketing tool by bottling companies – the original single shot crate is now a sophisticated multi-components assembly. Which of the optional ways of making a crate is the best one to use depends on several factors. ...

Kunststoffe international, 2007-10-21, Polyphenylene Sulfide (PPS)
Polyphenylene Sulfide (PPS) Production Capacities Growing in Double Figures (Trade-fair-pre-report K 2007) Polyphenylene sulfide (PPS) is a semicrystalline high-performance plastic that is constantly opening up new fields of application due to its special range of properties. Rising demand for load-bearing materials has ensured, especially in the last few years, that the special properties of the polymer have increasingly attracted the attention of developers. In order to be in a position to m...

Kunststoffe international, 2007-10-21, Polystyrene (PS)
Polystyrene (PS) Consumption Stagnating (Trade-fair-pre-report K 2007) Polystyrene producers continue to talk of a “difficult market situation.” The global annual market volume has been stagnant at around 11 million t since 2002. New application areas in coming years should ensure some growth in consumption, albeit slight (approx. 1.8% p.a.). Annual consumption is expected to reach 12.2 million t by 2011. Wolfgang Glenz Growth rates for polystyrene have failed to exceed growth in gross nat...

Kunststoffe international, 2007-10-21, Window for the Loading Door
Window for the Loading Door Design Highlight Two plastic components, a ring on the inside and viewing glass on the outside, cover the loading door of a Miele washing machine in such a way that no assembly elements are visible – and customers almost find themselves developing a sense of appreciation for the esthetics of household appliances. The factory assembly unit, which combines all the individual parts into a single module, provides an object lesson in mastering the complexities of large-s...

Kunststoffe international, 2007-11-21, Flexible Production of Food Packaging
Flexible Production of Food Packaging Stack Molds with Interchangeable Inserts Thin-walled food packaging presents severe challenges to moldmakers. A newly designed 2x4 cavity stack mold for containers is modular in structure to allow processors to produce different packaging sizes. Carefully thought-out details ensure its reliability and cost effectiveness over millions of cycles. Thomas Adolph The market is highly competitive; quality demands are putting pressure on designers – to say th...

Kunststoffe international, 2007-12-17, Logistics and Know-how Rule the Market
Logistics and Know-how Rule the Market Commodity Plastics All the producers of commodity plastics are expecting a positive future. Market is growing and enterprises are in an optimistic mood. They anticipate growth to take place not mainly in Northern America and Western Europe, but in Eastern Europe, the Middle East, Asia and India. And this is because two-digit growth rates are no rarity here, today. Stefan Tamsen Sounding like some sort of philosophy, plastics manufacturers are pronounc...

Kunststoffe international, 2007-12-17, More Complexity, Speed and Intelligence
More Complexity, Speed and Intelligence Part 1: Molds in Operation Injection molds are the interface and eye-of-the-needle between the product developer’s ideas and what is possible in polymers. Their current level of achievement – to name a few: combination of technologies, integration of additional tasks, speed – is impressive. Georg Krassowski Numerous approaches and examples of intelligently equipped molds reveal how much potential there is for controlling complex processes better and ...

Kunststoffe international, 2007-12-17, Not off the Rack
Not off the Rack Tubes and Profiles A large variety of products combined with specific requirements for individual customers means there is a wealth of approaches and solutions for extruding pipes and profiles. But extruders are not alone in the limelight. Peripherals tailored to the process are getting increased attention. Paul Gorczyca Growing market demands insist on the further development of our available technologies. This, in turn, is causing the competencies in individual branches ...

Kunststoffe international, 2007-12-17, Seamless and Smooth
Seamless and Smooth Materials Handling Hoses for conveying abrasive bulk goods such as grain, sand, gravel or also plastics pellets must have a smooth interior surface, as otherwise the conveyed goods will cause increased wear at the seams and joints. In the past, such hoses were mostly manufactured of rubber. Thanks to a new process, it is now possible to produce smooth, seamless hoses of polyurethane (PU), which could become a serious rival for the previously dominant rubber hoses in many ap...

Kunststoffe international, 2008-01-15, Elastomer Industry Has Understood
Elastomer Industry Has Understood Elastomers (Trade Fair Report K 2007) The elastomer industry has become ever more heavily dependent on automotive manufacture (approx. 68 % of elastomer products are processed in this sector). Increasing raw material and energy costs associated with spiraling oil prices and growing price pressure due to cheap imports from Asia and Eastern Europe have severely shrunk margins despite continually rising sales. The European, and in particular the German, elastome...

Kunststoffe international, 2008-01-15, Made in Greater China and Taiwan
Made in Greater China and Taiwan Country Report (Trade Fair Report K 2007) K 2007 provided an ideal opportunity for determining the geographic distribution of the global technological supply of machinery for plastics processing. Our Asia correspondent, Petra Thomas-Hasenzahl, spoke to exhibitors from China, Hong Kong and Taiwan about their technologies and their strategic direction. Petra Thomas-Hasenzahl In the People’s Republic of China also the packaging sector is the largest user of pla...

Kunststoffe international, 2008-02-17, Calculating Large Filter Surface Areas
Calculating Large Filter Surface Areas Melt Filtration The demanding standards regarding melt quality in fiber and film systems require the use of large-area melt filters. To design and optimize such filters, a computation tool has been developed that allows the essential process data such as required pressure, throughput distribution or residence time to be determined. Today, there are many different filtration systems to filter polymer melts for a variety of applications. In addition to sc...

Kunststoffe international, 2008-02-17, Connecting Material
Connecting Material Miniaturization For mobile phone production instead of mechanical connectors extremely thin tapes are used. They hold all the parts together reliably on small areas, are extremely temperature resistant and adapt themselves flexibly to new mobile phone models – and all that with economical and process reliable workability. In Germany since August 2006 there have been more mobile communication contracts than inhabitants. There were about 86 million at the end of 2006 and th...

Kunststoffe international, 2008-02-17, Growth in Specialties
Growth in Specialties Compounds, Additives, Distribution Compounding is enjoying renewed importance. The resurgence of compounding is typically happening in sectors that cannot be served by masterbatches. For instance, systems with high filler levels may be involved or it may be a matter of achieving the finest possible distribution within the compound. Newly developed additives are permitting numerous customized innovations. The industry must seriously get to grips with the new European Che...

Kunststoffe international, 2008-02-29, EPDM and HNBR versus Summer Smog
EPDM and HNBR versus Summer Smog Elastomer Hoses for AdBlue Nitrogen oxides in exhaust gases of diesel engines can be neutralized by adding ammonia to selectively convert them to nitrogen and water. So-called SCR systems use aqueous urea solutions (AdBlue) as the NH3 source for this. To transport the solutions from the tank to the catalyst, the technology relies on chemically resistant hoses made from specialty chemicals, such as EPDM. Martin Mezger When technologically innovative solutions...

Kunststoffe international, 2008-02-29, Integrated Folding Transparency
Integrated Folding Transparency Polycarbonate Lamella Roofs Bayer Material Science AG as a raw material supplier works independently on innovative thought provoking concepts for the future of automobiles. A current example of this is the prototype of a completely transparent, highly integrated and lightweight polycarbonate lamella roof. It is a completely new design extending the range of conventional sliding and folding roofs made out of PVC and textiles. In the light of climate change and ...

Kunststoffe international, 2008-04-14, From the Pressure to Innovate to a State of Exhaustion
From the Pressure to Innovate to a State of Exhaustion VDI Injection Molding Conference 2008 The calendar had its way: the annual conference of injection molders in Baden-Baden, Germany, took place already at the end of January this year. The theme of this year’s event was "Innovation and Productivity", and the organizers focused on current developments in processing technology. Practical assistance was offered to those who have to withstand the everyday pressures associated with succe...

Kunststoffe international, 2008-04-14, Performance Enhancements for Highly Filled Compounds
Performance Enhancements for Highly Filled Compounds Dispersing Additives Compounds with high filler loadings are difficult to process. This results in sub-optimal dispersion of the fillers in the polymer matrix, which also has a negative influence on the mechanical properties. A new additive concept now allows processing and properties to be improved. Bärbel Gertzen Jörg Garlinsky Fillers are used in polymers in many ways to improve properties or reduce costs. A wide range of various diff...

Kunststoffe international, 2008-05-10, Hand in Hand with the User
Hand in Hand with the User Machine Technology The development of the fully electric Select series was strictly based on an analysis of customer needs. In doing this there was to be no dogmatic prescription in the choice of drives. The prototype of the machine presented at K2007 was developed over a period of a year. Dudu Cosgun Rémi Savey Guido Radig Fully electric machines have now been under discussion for almost 30 years. In this period two tendencies have been identifiable: on the one ...