Spray technologies from KraussMaffei

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1 APPLICATION-SPECIFIC SOLUTIONS FOR PREMIUM RESULTS

2 IN PARTNERSHIP WITH INDUSTRY KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide Automotive White Goods Construction Life Sciences Whatever you aim to achieve in plastics or rubber complete etrusion lines is used in many processing, KraussMaffei is your partner. We are industries, including chemicals, pharmaceuticals, the only company with intensive epertise across automotive, construction, furniture and packaging. the three main engineering fields. And we have a strong track record in integrating this epertise to People for Plastics develop new processes and systems. We are the people for plastics. We are your partners from the first eploratory discussion, Ready for any challenge through development to commissioning, servicing Our Injection Molding Machinery Division and operating your system, and final disposal. At all supplies machinery and systems from 35 to 4,000 times, you are assured of outstanding competence tonnes for standard applications and for all in planning and engineering, as well as reliable and processing variants, together with fully automated fast spare parts, service and support. solutions. We have a strong customer base in all the relevant industries worldwide. Adding value for customers Our Reaction Process Machinery Division supplies We put our epertise to work for your success. machines and complete systems for processing With machine ranges engineered for modular- polyurethanes and other reactive materials. ity, we can deliver application-specific solutions Completing our product portfolio, Automotive based on our wide range of standard modules and Component Systems supplies foam molds, cutters specially engineered solutions. This strategy offers and routers. Our customer base is wide, with a customers technical and cost advantages. focus on the automotive, construction and white appliances industries. Close to customers around the world Our Etrusion Technology Division supplies As an international company, KraussMaffei has machinery and systems for compounding, for pipe, a presence in all the major markets for the plastics profile and sheet etrusion, physical foaming, and and rubber processing industries and employs the production of technical rubbers and inter- around 3,000 people worldwide. Our sales and mediates for tire production. Machinery from the service network keeps us close to all our company s range from single etruders to customers around the world. Electrical / Electronics

3 Premium application-specific solutions with KraussMaffei s miing head range Packaging Spraying a PUR system into an open mold, or directly onto preformed intermediate products, has substantial benefits. The technical advantages of spraying include great freedom in parts design, simple solutions for realizing comple part geometries, uniform PUR layer thickness and premium surfaces. There are also cost benefits, such as lower investment cost for molds. KraussMaffei supplies the complete, coherent systems that are essential for ecellent results in PUR spraying. In addition to the application-specific miing head, the system includes the tooling, the premiing and metering systems and downstream equipment.

4 Door trim panels and instrument panels APPLICATION-SPECIFIC SOLUTIONS Spray skins: a technology with almost limitless prospects The look and feel of the surface gives consumers of processing even very small output volumes very the first impression of the quality of a part. With a precisely. This means optimal distribution of the KraussMaffei spray system, you are always assured sprayed PUR material for constant thin wall thick- of uniform material distribution to produce spray nesses over large areas for low weight parts. The skins with uniform PUR thickness and premium result: faster cycles, higher productivity and lower surfaces. The length of the miing head lance can unit costs. Precision nozzles guarantee a reprodu- be specified to enable spraying of even comple cible spray jet even after a nozzle change. Air- geometries including undercuts and narrow supported spraying delivers a very good spray result gaps. Other advantages include ecellent miing in the output range 5 25 g/s. Another advantage quality. and rheologically optimized lance geometry is the option of interrupting the shot while the part that obviates the need for additional miers in is being sprayed to avoid the problem of material the lance. This simplifies cleaning and makes for piling up at the turning points. etremely long operating periods with no need to change the nozzle or the lance. Airless spraying with minimal overspray is possible at output rates between g/s. This reduces material, cleaning and maintenance costs. The systems are capable Miing head MK 2,0-2K - S - L Page 4

5 Sun roof Rear tray, honeycomb sandwich part APPLICATION-SPECIFIC SOLUTIONS Structural elements: lightweight and high-strength Structural parts need to combine two seemingly for very large parts and for applying a lightweight contradictory properties: light weight and high PUR coating over a very large area. Ecellent atom strength. KraussMaffei offers a range of standard ization results in minimal overspray and sharply- spray miing heads engineered on a building-block defined spray edges. This means cost savings for basis. This means we can supply optimal produc- materials, cleaning and maintenance. Miing heads tion solutions for parts that are both light and and nozzles are cleaned with air or solvent, depend strong, for throughput volumes from very small to ing on application specifications. very large, for processing high-speed PUR systems, Sandwich structure Fiber-reinforced outer layers Miing head MK 2,0-2K-S: output; g/s Miing head MK 3,0-2K-S: output; g/s Honeycomb inner layer

6 Cover element Step tread application -specific solutions Fiber composite spraying offers new design freedom for large-format parts KraussMaffei offers a Fiber Composite Spraying PUR material systems. One and the same miing (FCS) system as a fleible, cost-effective produc- head is capable of processing many different PUR tion method for large-format, fiber-reinforced systems. For instance, compact layers can be com- parts. FCS systems are already being used with bined with foamed layers, allowing even comple great success to produce parts for commercial parts to be manufactured in a one-stage process. vehicles and in applications in the construction Another task for FCS is spraying PUR systems with and furniture industries. high filler content. In most FCS processes, a singleshell mold made of resin, aluminum or steel is all Greater design freedom with coaial that is needed. A one-part mold is a cheaper option, fiber injection which could increase profitability especially for Endless roving is chopped to set lengths in a cutter small and medium-sized production runs. If both and the filaments are blown through a tube coa the front and reverse sides of the part must meet ially into the PUR spray jet. The completely closed high optical and functional standards, then fiber feed system minimizes fiber flight during processing. spraying is perfectly feasible with two-part molds. The fibers are very uniformly wetted with the PUR mi. Coaial fiber feed also means that the cutter unit need not be located directly at the miing head. The outcome is even greater freedom in part design, because the miing head can swing over 90 from its vertical position. Fiber content and fiber length are set to meet product specifications. Multicomponent miing head for more options The multicomponent miing head deployed in FCS processes opens the way to using a broad range of MK 6,0-4K-S-F Page 6

7 Front wall bulkhead soundproofing Floor mat application -specific solutions Soundproofing: a perfect fit For maimum effect, sound damping material materials, they have long lifespans. Proven nozzle must be in the right place. In a car, for eample, geometry results in clearly defined spray edges. The this means against the front wall bulkhead or in result: cost savings for materials and cleaning. The the floor carpet. T impingement miing in these spray miing heads guarantees outstanding miing quality even with The product specifications and operating conditions difficult miing ratios and relatively low processing for this type of soundproofing application are chal- temperatures. lenging, but KraussMaffei spray miing heads are engineered to meet them. They have been specially developed to process highly-filled systems, eg, with BaSO4 and chalk. Made using abrasion-resistant Miing head MK 10-2K - S - F Page 7

8 Tractor Same Deutz Honeycomb sandwich board APPLICATION-SPECIFIC SOLUTIONS Coating for custom surfaces and gluing for high strength Product specifications for many applications full. The miing head MK 2,0-2K - AS is ideal for demand attractive surfaces paired with high both continuous and discontinuous processing. functionality. With KraussMaffei spray It delivers outstanding miing performance for technology you can deliver both. small volumes of 8 20 g/s, and ensures the PUR is sprayed in thin uniform layers. Apart from Attractive optics and ecellent adhesion ensuring outstanding product quality, this keeps Compact PUR systems score on attractive optics raw materi al consumption to a minimum, helping and outstanding mechanical properties. Sprayed to cut unit costs still further. The shape of the directly onto the part or into a mold, they let you spray jet can be varied, with the help of horn air, eploit PUR s powerful adhesive properties to the from a full cone to an oval. At a spray distance of 350 mm, spray jet width is 300 mm. Because it is self-cleaning, the miing head helps to maimize uptime and productivity. Compact PUR systems Coating, etc. Miing head MK 2,0-2K - AS Ideal for continuous spraying with output 8 20 g/s LFI Page 8

9 CUSTOMER BENEFITS Spray technologies from KraussMaffei offer you substantial technical and cost benefits Spraying PUR systems into the open mold or investment in your mold is lower, because spraying directly onto preformed intermediate products is a requires only one mold half and no mold closing growth area, because spray techniques can deliver and locking systems. Shorter cycles mean higher major benefits. productivity. Technical benefits Coherent concept Spray technology means ecellent reproduction To achieve consistently high product quality in a of comple geometries and fine surface graining, spray process, it s essential that all modules of the optimal material distribution for large and small reaction system are engineered to operate perfectly parts, uniform wall thicknesses and low weight/ together. KraussMaffei is a single-vendor supplier area ratios. Spraying is often the simpler process for the miing heads and all other system compo option, for eample for direct backfoaming onto nents molds, premiing and metering systems sensitive skins or films without swapping molds and downstream units. The KraussMaffei TechCenter or transfer operations. in Munich is the ideal place to run trials on potential spray technologies for your proposed Cost benefits project. Our coherent concept makes sure that While the technical advantages can increase your your KraussMaffei manufacturing system will run competitive edge indirectly, there are also direct reliably and cost-effectively day in, day out. cost benefits to spray technology. For eample, Overview of KraussMaffei spray miing heads Application MK 2,0-2K-S-L Spray skins MK 2,0-2K-S MK 3,0-2K-S Structural elements Fiber composite spray MK 2,0-2K-AS MK 10-2K-S-F MK 6,0-4K-S-F Soundproofing Premium surfaces Gluing g/s g/s g/s g/s 8 20 g/s Output g / s airless air-supported * g/s 5 25 g/s g/s * g/s 4 components Page 9

10 SERVICE WORLDWIDE Service, support and spare parts when you need them, where you need them Rely on us for a fast and competent response to Customer trials and prototyping in our test lab all your service needs anywhere in the world. The Reaction Process Machinery Division operates Whatever you need from troubleshooting and a test lab fitted with the latest machinery and training to spares or repairs we re on the job. equipment. We can run trials, produce prototype parts and fine-tune processes on your behalf. We We re dedicated to supplying service quality on a can work with you to test and evaluate processes, par with the outstanding quality of our machines machines and equipment in order to identify the and systems. We offer far more than spare parts best approach for a particular project. Our highly- and hotlines. We ll work with you to choose the qualified application engineers are there to help you. best and most cost-effective solution for your operation. We ll help you test new applications Training with high hands-on content and we ll plan customized service packages. Courses are held in our lab and training centre, or, optionally, on your premises. We offer All-round service clearly-structured basic and advanced training in Our service offering is broad. We ll configure your operation, process control and maintenance for system, install and commission it, train your staff, KraussMaffei reaction process machinery. On plan measures to minimize your downtime risk and request, we ll plan and hold special courses on maimize productivity, and carry out maintenance, topics of your choice. All participants spend a high repairs and upgrades. You ll find us fast, reliable proportion of their training working hands-on with and competent. Our hotline is manned by highly- original KraussMaffei machines. A well-structured trained and eperienced service technicians. training program produces skilled operators and If necessary, we ll get a technician to you quickly. technicians, which will positively impact your Remote diagnosis, interfacing directly with your up-time and productivity. machine s control system, can be a practical alternative. Spares for all important wear parts are available at short notice. We re continuously epanding our service network to speed up spare parts shipment. Talk to us about the right service solution for your business.

11 KraussMaffei Reaction Process Machinery Worldwide KraussMaffei Technologies GmbH Munich, Germany Viersen, Germany Georgsmarienhütte, Germany Krauss-Maffei U.K. Ltd. Krauss-Maffei Italiana S.r.l. Warrington, UK Abbiategrasso, Italy OOO BKM Berstorff KraussMaffei Moscow, Russia Krauss-Maffei Corporation Florence und Detroit, USA Krauss-Maffei Korea Ltd. Seoul, Korea Krauss-Maffei Corporation Meico City, Meico Krauss-Maffei Plastics Machinery (Shanghai) Co., Ltd. Krauss Maffei Andina Shanghai, China Bogota, Colombia Krauss-Maffei Japan KK Krauss-Maffei do Brasil Ltda. Okazaki, Japan São Paulo, Brazil How to contact us Apart from you can contact us on our Reaction Process Machinery Service service hotline or by post at this address: KraussMaffei Technologies GmbH Service hotline Phone: Fa: Krauss-Maffei-Str Munich Germany

12 KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide. KraussMaffei machines and systems are used wherever plastics and rubber are converted into products. As a knowledge-driven technology company, we build on many decades of eperience and a strong Using KraussMaffei systems for PUR spraying makes it easy to achieve outstanding results. We offer complete systems as a single-vendor supplier. Our systems are engineered on a modular basis for easy customization. We supply application-specific miing heads, teamed with tooling, premiing and metering systems and downstream units. Technical benefits include great freedom in parts design, simple solutions for comple geometries, uniform layer thicknesses and premium surfaces. In addition there are direct cost benefits, such as lower investment costs for molds, shorter cycle times and higher productivity. KraussMaffei Technologies GmbH Krauss-Maffei-Strasse Munich Phone Fa WE. 2nd edition 09/10. RPM 026 A PRO 2007 GB KraussMaffei reserves the right to make technical changes. commitment to research and development.