On the direct way to profitability Injection Molding Compounder IMC. Krauss-Maffei Kunststofftechnik GmbH, 2007

Transcription

1 On the direct way to profitability Injection Molding Compounder IMC Krauss-Maffei Kunststofftechnik GmbH, 2007

2 2 Agenda General principle of the Injection Moulding Compounder Working principle Differences and advantages Automotive applications Front End carrier development State of the art applications Outlook Opportunities Use of natural fiber Local reinforcement

3 3 Agenda General principle of the Injection Moulding Compounder Working principle Differences and advantages Automotive applications Front End carrier development State of the art applications Outlook Opportunities Use of natural fiber Local reinforcement

4 4 Get the Benefit together IMC Injection Moulding Compounder Principle Injection Moulding: Single screw Material processing Discontinuous process Extrusion: Twin screw Material compounding Continuous process

5 5 Your system...is out of one hand One supplier - Krauss Maffei Simple integration Injection molding Reaction technology Extrusion

6 6 Continuous and discontinuous Two in One IMC Injection Moulding Compounder Principle Melt buffer Weighing, Dosing and conveying systems Shut-off nozzle Start up valve with container Re-direction valve Twin screw extruder MX or CX- Clamp Shot-Pot- Injection piston

7 7

8 8 What makes an IMC suitable for long glass fiber applications? Long glass fiber IMC with platform scale Rovings Plastic matrix Platform scale

9 We know, what we are talking about... Industrial References 9 AKsys Germany Köngen KM MX IMC Krauss Maffei Injection Molding Compounder

10 10 Unbeatable combination of properties IMC Injection Moulding Compounder Main Benefit 1. Lower material cost 0,30 /kg-1,00 /kg 1. Reduces process steps No half-finished products necessary Specialties for low tonnages 2. Improved material quality IMC IMC 3. Highest flexibility 2. Longer fibers Better homogeneity Lower mass temperature 3. Fiber reinforcement Blends Fillers

11 11 Less is more... Less cost, more profit Material cost savings Save one stage s added value C O M P O U N D I N G I M M A Transport Dosing Predrying B Transport Dosing Plastification Homogenisation Degassing Granulating Cooling Predrying Transport Silo Weighing Packaging Transport Silo Transport Predrying Transport Plasticizing C Transport Dosing Injection molding D Transpor Dosing t A Transport Dosing Predrying 0,30 1, 00 /kg B Transport Dosing Plastification Homogenisation Degassing C Transport Dosing Injection molding D Transport Dosing I M C

12 12 Cost savings yes, but with the right starting point Material cost savings Reduction of part cost Consumer Technical parts Material Machine Mold Labor Material Machine Mold Labor

13 13 Long fibers out of the nozzle Take your chance! Long glass fiber Fiber length measurement Fiber length distribution out of the nozzle 40% 35% 33% 36% 30% weight proportion 25% 20% 15% 10% 5% 3% 8% 17% 3% 0% 1 mm < 5 mm 5 mm < 10 mm 10 mm < 30 mm 30 mm < 50 mm 50 mm < 70 mm > 70 mm Fractions Measured by IKT Stuttgart, PP 30 % GF, Burned for 3 h at 550 C, sieving method, weight distribution, sample out of the nozzle

14 14 One for all Do you know a more flexible system? Highest flexibility Material choice Fibers Longer fibers and homogenous dispersion /to 300 /to 300 /to Blends Specialties - Reactive Blends, fiber reinforcement,... Fillers High fill grades, substitution possibilities Benefit: Material cost savings At least 0,30 /kg Almost every thing is processable

15 15 Constant effective screw length No change of material quality Constant screw length Constant material quality Standard Inline compounding Length A Constant length Length B

16 16 Wider field of application and less screw wear High plasticizing and throughput capacity Maximum throughput With small screw diameters No injection pressure on screws Less stress Throughput is independent of screw speed Low mass temperature Benefit: Real enlarged working range Significant less wear in comparison to single screw Reduced cooling and cycle time Throughput in kg/h Injection Moulding Compounder Standard Shot weight in kg Example: SP24500, PP GF 30 IMC: D Ex= = 81 mm, D Kolben = 165 mm, 300 1/min max. Standard: D= 165 mm, 60 1/min max., plasticizing time = 50 % cycle time

17 17 The longer it runs, more stable gets the process! Clear-cut documentation Continuous dosing Discontinuous mode Continuous mode Throughput of one dosing unit Nominal throughput Throughput of one dosing unit Nominal throughput Plasticizing Time Start-up Production Time In the part undefined defined

18 18 Material responsibility We assist you Continuous extrusion process Clear-cut documentation Ongoing cycles Screw speed extruder Percentage of single components Mass temperature Control of roving quantity Throughput

19 19 The IMC technology Worldwide in use References 7 x Canada 4 x USA 6 x France 1 x Spain 14 x Germany 1x Iran 1x Russia 1x China 1 x Mexico Status: 1/2007

20 20 Next step are trials Lab machinery Detroit KM MX IMC KMG 81, 23 D, 110 kw Shot volume: ~ 4 liters

21 21 Agenda General principle of the Injection Moulding Compounder Working principle Differences and advantages Automotive applications Front End carrier development State of the art applications Outlook Opportunities Use of natural fiber Local reinforcement

22 Beginning with GMT compression molding the direct compression molding process to follow. 22

23 ending up with the direct injection moulding process! No rework, no scrap material 23

24 State of the art Automotive Underbody shields 24 Source: HP Pelzer Application example

25 State of the art Automotive Door module 25

26 State of the art Automotive IP structural-duct assembly 26

27 State of the art not only glass fiber! Automotive Sound insulation 27

28 and the potentials are not yet spent Automotive Rear door 28

29 and the potentials are not yet spent Automotive Exterior parts with back injected foil 29

30 30 Agenda General principle of the Injection Moulding Compounder Working principle Differences and advantages Automotive applications Front End carrier development State of the art applications Outlook Opportunities Use of natural fiber Local reinforcement Combination with fiber processes

31 Process steps for natural fiber reinforced composites production Direct processing at IKT Stuttgart 31 Compounding/ Compression-Process: several process steps Compounding PP/MAH- Graft copolymer ZSK 30, 4 kg/h Granulate Compounding PP/NF- Composites ZSK 30, max. 5 kg/h Extruded strand t > 1 d Compression molding of sample plaques 20 min heating at 180 C and 15 min cooling from C Compounding/ Compression-Process : one-step-process MAH grafting on PP NF compounding Extruded strand Compression molding of sample plaques ZSK 40, 20 kg/h t < 15 s 2 min at 80 C cooling Compounding/Injection molding-process (IMC): one-step-process MAH grafting on PP NF compounding Injection moulding of sample plaques Source: IKT Stuttgart ZE 40, 20 kg/h 25 s at 20 C cooling

32 We know, what we are talking about... Packaging 32 Application Transportation box PP 40% wood pellets, 2% coupling agent ~ 60 sec cycle time Innovation Injection Moulding Compounder KM MC IMC Inline-compounding of fillers Gentle melting process and low mass temperature Value Material substitution by cheap fillers Wood: 0,15 /kg Exact temperature control for sensitive materials Short cycle time due to shorter cooling times

33 Properties of fiber reinforced thermoplastic processes 33 Injection Molding Design stiffness, number of pieces Non-reinforced Short fiber Long fiber Roving Mat Injection Compression Molding Direct processes Fabric Compression Molding Uni-directional Source: Prof. Schemme, Fh Rosenheim Rigidity, material cost, fiber length

34 34 Full plastic hybrids: High mechanics, no rework, design freedom L-LFT-IM In combination with fabrics High basic rigidity due to use of fabrics Source: Neue Materialien Fürth, LKT Erlangen Diagonal ribs for high design stiffness

35 and the potentials are not yet spent Automotive Structural parts 35

36 Fiber-reinforcing processes within Krauss Maffei 36 Faserverstärkte Kunststoffe FVK Fiber-Reinforced Plastics FRP Duroplastische Matrix thermosetting matrix Thermoplastische Matrix thermoplastic matrix Presstechnik Compression Molding technology CM Reaktionstechnik Reaction technology R Spritzgießtechnik Injection Molding technology IM Spritzgießtechnik Injection Molding technology IM Presstechnik Compression Molding technology CM KurzFaser KF Short Fiber SF LangFaser LF Long Fiber LF KurzFaser KF Short Fiber SF LangFaser LF Long Fiber LF KurzFaser KF Short Fiber SF LangFaser LF Long Fiber LF Halbzeug semi-finished Halbzeug semi-finished Direktverfahren* Direct process D Halbzeug semi-finished Halbzeug semi-finished Halbzeug semi-finished Halbzeug semi-finished Direktverfahren* Direct process D Reinforced Reaction Injection Molding R-RIM Structural Reaction Injection Molding S-RIM Resin Transfer Molding RTM Long Fiber Injection LFI Bulk Molding Compound (Injection Molding) BMC-IM Sheet Molding Compound (Injection Molding) SMC-IM Short Fiber Granulate Injection Molding SFG-IM Long Fiber Granulate Injection Molding LFG-IM G-LFT-IM Direct process Long Fiber Injection Molding D-LFT-IM (IMC) * natural fiber usable Pour Spray Molding PSM