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    Engineering Passion

    Foam molds for perfect parts

    The right moldfor every application

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    Foam moldsFacts and figures2

    Facts and figures regarding our foam molds

    Consumer goodsConsumer goods

    Our foam molds can also be put to a wide variety of uses in the construction,

    electrical/electronics and white goods industries.

    Automotive AutomotiveAutomotive

    Consumer goods

    Applications

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    Foam molds for perfect partsThe right moldfor every application

    From pouring and foam-molding to backfoaming KraussMaffei makes molds for creating the perfect parts

    every time. Molds for open or closed pouring are made

    of steel or aluminum and/or with a polymer surface if

    required. Our molds are engineered as custom tools forspecific applications and ensure process-specific heating.The molds have demolding concepts for damage-free

    demolding, are fitted with product-specific seal systems

    and come with wear-resistant surfaces, if required. This

    means that process, machinery, mold carriers and molds

    are perfectly integrated.

    The various molding processes at a glance

    Clear Coat Molding process (CCM) Processing flexible foam

    Processing rigid foam

    Processing semi-rigid foam Manufacturing glassfiber-reinforced parts (LFI-PU)

    Manufacturing flexible integral foam

    Manufacturing parts for white goods

    Producing special molds

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    Multiple applicationsOur foam molds are used to makeall kinds of products

    Office furniture

    Jet skis Boat hulls

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    Car roofs

    Instrument panels

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    Foam moldsMolds for Clear Coat Molding (CCM)6

    Clear Coat Molding (CCM) is an

    automated process for coating

    premium quality substrates,

    e.g. luxury wood veneers, with

    a transparent two-component

    PU system. Typical applications

    are trim parts for vehicle inte-

    riors, consumer electronics

    and the furniture industry.

    In contrast to other methods of coating

    such parts, CCM is a one-step process.

    The substrate item is positioned in the

    mold. When the mold closes, there is a

    gap the thickness of the coating layer left

    free. This gap is flooded with transparentpolyurethane in a high-pressure process.

    The CCM process produces a premium

    quality coating in a relatively short time.

    Molds for Clear Coat Molding (CCM)Premium quality coating in next to no time

    Your benefits:

    Premium quality coatings in just

    one step

    Superior part quality thanks to

    repeatable processes

    High production rates Seal tightness combined with

    venting capability

    Precise temperature control and the

    system's stable, repeatable process

    ensure that the manufactured parts meet

    extremely high criteria for visual quality.

    Stable and repeatable process for

    superior part qualityThe production system has a mold car-

    rier and a mold. The mixing head is

    mounted on a centrally positioned robot,

    so that it can dock alternately onto the

    molds to discharge the CCM material

    into the cavities. The wait times between

    shots are relatively short to eliminate the

    risk of problems with hardened material

    residues. This configuration also makes it

    possible to achieve high production rates.

    Combining precision seals with ventingcapability

    CCM molds have to combine a close

    tolerance seal with venting capability.

    The coating needs to compensate for

    manufacturing tolerances from previous

    processes. Maximum seal tightness must

    be guaranteed with minimal flash, which

    means the substrate to be coated needs to

    be held firmly in place.

    Our CCM molds are perfectly adapted to the requirements of the process

    Molds:

    a) With highly-polished steel surfaces

    b) With contoured nickel shell as insert

    All molds with process-specific heating:

    a) With inserted heat-transfer lines

    b) With deep-hole drilling

    Metal seal edges, manually finished/bedded in, milled or eroded

    With optimized demolding concepts for damage-free demolding

    With product-specific seals in the mold to prevent flash or over-foaming

    Process-specific brackets or fixtures for holding inserted substrates

    Process-specific venting

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    77CCM mold inmold carrier

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    Mold carrier with mold for door armrest,

    front foaming process

    Molds for flexible foam systemsHigh output and premium part quality

    Foam moldsMolds for flexible foam systems8

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    Flexible foam systems (hot

    and cold foam) are processed

    on high-pressure metering

    machines. High-pressure

    metering means high-pre-

    cision metering for PU com-

    ponents, while high mixing

    quality ensures splash-free

    pouring into the mold.

    Producing flexible foam from PU has two

    major advantages: one is a very high out-

    put, the other is excellent quality.

    Flexible foam products for transport

    and furniture applicationsFlexible foams are produced to com-

    ply with customer specifications, for

    example, the density can vary between

    35 - 60 kg/m. Ergonomic seat cushions

    and seat backs can be produced in a

    single work process by pouring differ-

    ent density PU foam to create different

    hardness zones the resulting products

    are outstandingly comfortable and dura-

    ble. Molds are adapted to the special

    demands of processing flexible foam,

    with aluminum, special epoxy resin or

    steel surfaces and with process-specific

    heating using either cast heat-transfer

    lines or deep drilled holes. This makes

    it possible to produce a wide range of

    seat cushions, armrests and seat backs

    with varying hardness zones using the

    same PU system and one and the same

    production unit. Upholstery fabric can be

    inserted in the mold and foam backed,

    and inserts can be foamed-in.

    It is also feasible to foam onto a sub-

    strate material; the parts can subse-

    quently be covered with selected dcor

    material.

    Your benefits:

    High level of productivity

    Optimum part quality

    Customer-specific solutions

    Manually-finished metal seal edges

    Molds are adapted to the special

    demands of processing flexible foam Broad range of applications

    These molds are specifically adapted to the flexible foam process:

    Molds:

    a) Surfaced with epoxy resin

    Temperature-resistant up to 150 C

    Resin applied in the front-pouring or surface-coating process

    b) With aluminum surface Cast aluminum, inner surface polished

    Milled from cast aluminum or aluminum block, inner surface polished

    Special aluminum capable of taking a high-gloss polish

    c) With steel surface, milled and polished

    All molds with process-specific heating

    a) With inserted heat-transfer lines

    b) With cast heat-transfer lines

    c) With deep-drilled holes

    Metal seal edges, manually finished/bedded in, milled or eroded

    Plastic seal edges stamped or coated, with specially filled polymer resins

    Product-specific polymer seals in the mold to prevent flash or over-foaming

    Process-specific brackets or fixtures for padding aids, inserts or stiffening ele-

    ments

    Process-specific venting to remove gases generated during foaming from the mold

    safely and without damaging the part

    Molds engineered for foaming in open or closed molds

    Molds engineered for use with a KraussMaffei mold carrier or self-contained,

    depending on target production volumes

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    Foam moldsMolds for rigid foam systems10

    PU rigid foams are used in

    civil engineering, in industrial

    plants, in plumbing and heat-

    ing applications, in air condi-

    tioning and refrigeration and

    in district heating applications.

    The foam systems meet the

    physical criteria for buildings

    and comply with the legal

    requirements in different

    sectors of the construction

    industry.

    Proven high mixing quality for consistent

    product qualityRigid foam systems have outstanding

    thermal insulating properties, even with

    very thin walls. Their bulk density can be

    set within a wide range. The rigid foam

    creates a self-adhesive bond with differ-

    ent outer layers, the composite elements

    of which are highly stable. The foam's

    good flow behavior opens up wide design

    variability, meaning that even complicated

    cavities can be filled.

    Molds for rigid foam systemsConsistently high product quality

    Your benefits:

    Outstanding thermal

    insulating properties

    High stability

    Good flow behavior

    High design variability

    These molds are specifically adapted to the rigid foam process:

    Molds:

    a) Surfaced with epoxy resin

    Temperature-resistant up to 150 C

    Resin applied in the front-pouring or surface-coating process

    b) With aluminum surface Cast aluminum, inner surface polished

    Milled from cast aluminum or aluminum block, inner surface polished

    Special aluminum capable of taking a high-gloss polish

    With etched graining in the aluminum

    c) With steel surface, milled and polished

    With etched graining in the aluminum

    b) With nickel shell as contour insert

    All molds with process-specific heating

    a) With inserted heat-transfer lines

    b) With cast heat-transfer lines

    c) With deep-drilled holes

    Metal seal edges, manually finished/bedded in, milled or eroded

    Plastic seal edges stamped or coated, with specially filled polymer resins

    Optimized demolding concepts for damage-free demolding

    Product-specific seals (polymers) in the mold to prevent flash or over-foaming

    Process-specific brackets or fixtures for parts to be encapsulated, inserts or stiff-

    ening elements

    Process-specific venting

    Molds engineered for foaming in open or closed molds

    Molds engineered for use with a KraussMaffei mold carrier or self-contained,

    depending on target production volumes

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    Foam mold for A pillar trim.

    Rigid foam back-formed onto film

    inserts.

    11

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    12 Foam moldsMolds for semi-rigid foam

    Molds for semi-rigid foamLow cost and energy efficient

    Semi-rigid polyurethane foam

    systems are used mainly for

    backfoaming films, skins or

    leather.

    Your benefits:

    Extremely low-cost production

    Short demolding times

    Resource and energy efficient

    The great advantage of semi-rigid foams

    lies in their cost-efficiency due to short

    demolding times, low material consump-

    tion and the ability to reduce material

    and energy consumption by using light-

    weight foams with low bulk density.

    Combining PU foams with PVC, ABS or

    PU films results in good adhesion. In the

    automotive industry, the use of foam for

    sound-proofing and to dampen vibrations

    makes for a more pleasant driving expe-

    rience.

    Foam mold for instrument panel,

    milled aluminum, polished surface

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    Foam mold for instrument panel made of cast aluminum

    with face-cast synthetic resin surface

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    These molds are specifically adapted to the semi-rigid foam process:

    Molds:

    a) Surfaced with epoxy resin

    Temperature-resistant up to 150 C

    Resin applied in the front-pouring or surface-coating process

    b) With aluminum surface

    c) Milled from cast aluminum or aluminum block, inner surface polished

    All molds with process-specific heating

    a) With inserted heat-transfer linesb) With cast heat-transfer lines

    c) With deep-drilled holes

    With product-specific sealing systems. There are a number of rigid and/or inflatable sealing systems available, combinations

    are also possible

    Process-specific brackets or fixtures for inserts or stiffening elements

    Process-specific venting to remove gases generated during foaming from the mold safely and without damaging the part

    Molds engineered for foaming in open or closed molds

    With several vacuum circuits for perfect positioning of molded skins

    Molds engineered for use with a KraussMaffei mold carrier or self-contained, depending on target production volumes

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    Foam moldsLong Fiber Injection molding (LFI-PU)14

    We are your highly competent

    partner for molds used in

    manufacturing structural

    components reinforced with

    long glass fibers.

    In the LFI (Long Fiber Injection) process,

    endless fiber from a roving is chopped to

    length in a cutter. A blower then separates

    the filaments. Immediately behind the cut-

    ting unit, the fibers are brought together

    with the PU from the mixing head and

    wetted with PU. The fiber/PU compound

    is poured into the open mold, as a sharply

    Molds for Long Fiber Injection molding (LFI-PU)Stable and lightweight parts

    Your benefits:

    Broad range of applications

    Extremely strong yet lightweight parts

    First-class surfaces with simple pro-

    cess combinations (IMP, film inserts)

    Moderate mold and machine costs

    High design variability

    focused spray cone, using a robotic arm.

    Once mold filling is complete, the mold is

    closed and the compound cures.

    Specific, localized properties

    Fiber lengths can be varied between 12.5

    and 100 mm and fiber content can bevaried continuously during pouring from

    0 to 50 percent. 50 percent is the limit to

    ensure good wetting with PU. Today the

    most commonly used PU systems are

    either compact or foamed. This means

    that the property profile of LFI is com-

    parable with that of SMC.

    LFI mold made from aluminum as combination mold for four differ ent parts

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    Long fibers, considerable freedom to

    design part geometries and the versa-

    tility of PU systems mean that the range

    of applications is very wide. LFI parts

    can vary from a small trim par t for a car

    interior to a large structural part with a

    Class A visible surface.

    15

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    The combination of a light, flexible foam core with a tough, compact skin generates characteristic

    product properties that are useful for three applications in particular.

    Molds for flexible integral foamTough skin and soft core

    Foam moldsMolds for flexible integral foam16

    Cable sheathingCable harnesses fixed into the required

    shape and direction with polyurethane

    are far easier to install, maintain and

    repair. Complete cable sheathing guar-

    antees reliable protection against mois-

    ture even under extreme conditions.

    Steering wheelsSteering wheels with an integrated air-

    bag cover need to possess a textured,

    non-slip surface structure, have low-

    temperature, impact strength and meet

    all safety design specifications. The

    scope for attractive design solutions is

    also very wide.

    Glass encapsulationIn glass encapsulation, glass panes are

    inserted in a mold and overmolded with

    a compact PU system. The PU material

    not only acts as a seal, but also com-

    pensates for manufacturing tolerances,

    which makes the automated assembly of

    the glass panes easier.

    Non-slip materials ensure that

    steering wheels are very comfortable

    and extremely safe to use.

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    Your benefits:

    Decorative surface with pleasant grip

    High abrasion resistance

    Good mechanical and chemical resis-

    tance

    Low thermal conductivity

    Moisture repellent

    Aluminum foam mold for overmolding plugs

    Foam mold for steel steering wheel with etched

    graining

    These molds are specifically adapted to the foaming process:

    Molds:

    a) Surfaced with epoxy resin

    Temperature-resistant up to 150 C

    Resin applied in the front-pouring or surface-coating process

    b) With aluminum surface Cast aluminum, inner surface polished

    Milled from cast aluminum or aluminum block, inner surface polished

    Special aluminum capable of taking a high-gloss polish

    With etched graining in the aluminum

    c) With steel surface, milled and polished

    With etched graining in the aluminum

    b) With nickel shell as contour insert

    All molds with process-specific heating

    a) With inserted heat-transfer lines

    b) With cast heat-transfer lines

    c) With deep-drilled holes

    Metal seal edges, manually finished/bedded in, milled or eroded

    Plastic seal edges stamped or coated, with specially filled polymer resins

    Optimized demolding concepts for damage-free demolding

    Product-specific polymer seals in the mold, to prevent flash or overfoaming

    Process-specific brackets or fixtures for parts to be encapsulated, inserts or stiff-

    ening elements

    Process-specific venting to remove gases generated during foaming from the

    mold safely and without damaging the part

    Molds engineered for foaming in open or closed molds

    Molds engineered for use with a KraussMaffei mold carrier or self-contained,

    depending on target production volumes

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    Optimal molds forpremium quality refrigerator doors and cabinets

    18 Foam moldsMolds for refrigerator doors and cabinets

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    Accelerated development

    cycles and tighter deadlines

    make it essential that plan-

    ning and designing processes

    for your PU plant and tooling

    are efficient and streamlined.

    Our considerable expertise in and

    detailed knowledge of the white goods

    industry mean that we can ensure all

    our molds are process-optimized for

    refrigerators and refrigerator doors.

    This includes any subsequent assembly

    processes. Optimized interface lay-outs ensure seamless communication

    between our molds and fixtures.

    We use advanced simulation and inno-

    vative calculation systems to design

    and plan your plant or molds. We also

    undertake CNC-supported mold manu-

    facturing in dedicated manufacturing

    facilities.

    New product designs and materials can

    often sideline planners and engineers

    with time-consuming questions and

    challenges. We believe it is important to

    harmonize the process, the plant and the

    tooling at the early stages of the project

    in order to avoid technical problems andhigh costs.

    Your benefits:

    Process-optimized tooling technology

    Advanced planning systems

    Considerable expertise gained over

    many years

    Mold for refrigerator cabinets Side-by-side refrigerator cabinet plug

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    One such example is the SkinForm pro-

    cess, a 2C injection molding process in

    which each component is itself a two-

    component reaction material. This cat-

    egory also includes molds for structural

    or sandwich parts, where a reaction cast-

    ing resin is key to bonding the differentlayers. Another special area is Spray-RIM

    molds where the part is produced by

    spraying a reaction mix into the mold.

    Each of these types of molds is specially

    adapted to the process. This starts with

    the choice of material for the mold

    KraussMaffei makes molds from plastic,

    aluminum or steel and includes the

    seals and venting system as well as the

    chosen slides, flaps, removable parts

    and inserts necessary for demolding themolded part.

    Molds can be made of a combination of

    materials and KraussMaffei can advise

    on the best combination for a specific

    application. Decisive factors are the num-

    ber of parts to be produced, the material

    being processed and the part geometry.

    Reaction molding molds can be built for

    the temperature range from 30 to 150 C.

    Molds must be tight, even at high temper-

    atures, the slides must move as specified

    and reliably, and the entire mold technol-

    ogy must function as specified for the life

    of the mold.

    KraussMaffei can provide pre-engineer-ing support from an early stage of prod-

    uct design and can follow this up with

    support as an extended workbench dur-

    ing the testing phase.

    In addition, we have expertise in and

    machinery for downstream die punching,

    trimming and routing processes, so that

    we can advise here too.

    Foam moldsSpecial molds

    Special moldsFrom ideas for parts to series production

    Special molds are needed for

    particular materials such as

    elastomer-modified Nylon

    or Caprolactam and PU elas-

    tomers such as Technogel.

    KraussMaffei has the opti-

    mal solution for you for these

    materials too.

    Your benefits:

    Comprehensive knowledge of special

    materials

    Specific mold development for specific

    tasks

    Long-lasting operability

    Support throughout the entire process

    chain

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    Mold for a caprolactam pulley.

    Properties:

    Polished surface

    Temperature 140 C

    Four external slides and a core pull

    Caprolactum poured into the closed

    mold

    All molds and fixtures are specially adapted to process requirements

    Molds:

    a) Surfaced with epoxy resin

    Temperature-resistant up to 150 C Resin applied in the front-pouring or surface-coating process

    b) With aluminum surface

    Cast aluminum, inner surface polished

    Milled from cast aluminum or aluminum block, inner surface polished

    Special aluminum capable of taking a high-gloss polish

    With etched graining in the aluminum

    c) With steel surface, milled and polished

    With etched graining in the aluminum

    b) With nickel shell as contour insert

    All molds with process-specific heating

    a) With inserted heat-transfer lines

    b) With cast heat-transfer linesc) With deep-drilled holes

    Metal seal edges, manually finished/bedded in, milled or eroded

    Plastic seal edges stamped or coated, with specially filled polymer resins

    Optimized demolding concepts for damage-free demolding

    With product-specific polymer seals in the mold to prevent flash or over-foaming

    Process-specific brackets or fixtures for parts to be encapsulated, inserts or stiffening elements

    Process-specific venting to remove gases generated during foaming from the mold safely and without damaging the part

    Molds engineered for foaming in open or closed molds

    Molds engineered for use with a KraussMaffei mold carrier or self-contained, depending on target production volumes

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    22 Foam moldsFurther information

    Further informationwhich might also interest you

    Are you looking for the appropriate

    solution for post-mold processing and

    your system business?

    We offer composite fiber solutions for

    sophisticated lightweight components and

    PU rigid foam systems for use in the white

    goods industry and for manufacturingpanels and sandwich parts.

    The following brochures are available in

    print or to download:

    Fiber composite solutions for sophisti-

    cated parts

    Innovative and profitable solutions for

    white goods and insulation

    You can find our brochures and

    flyers on other topics online at:

    www.kraussmaffei.com.On request, we would also be happy

    to send you information and technical

    data for our products free of charge.

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    The KraussMaffei Group has a global presence.

    Countries with subsidiaries are marked in dark blue.

    In the white-colored regions, the Group is represented

    by over 570 sales and service partners.

    KraussMaffeiA strong brand in a unique global group

    Cross-technology system and

    process solutions

    Whether in Injection Molding, Reaction

    Process Machinery or Automation the

    KraussMaffei brand stands for pioneer-

    ing and cross-technology system and

    process solutions in plastics processingworldwide. For decades, our expertise,

    innovative ability and passionate commit-

    ment to plastics engineering have been

    your competitive edge. As a cross-indus-

    try system provider, we offer you modular

    and standardized systems as well as

    solutions customized to your needs.

    There for you around the world

    With our worldwide sales and service

    network, we offer our international

    customers an excellent basis for a

    successful business relationship. Due

    to the close proximity to our customers,

    we are able to answer your individualinquiries very quickly. We work out the

    best possible technical and economical

    solution for your product and production

    requirements together with you. Test our

    machine technology for your applications

    and let our experts put together an indi-

    vidualized service package for you.

    Individualized service

    Our employees from customer service,

    application technology and service help

    you with your questions and needs on

    every topic dealing with machines, sys-

    tems and processes around the globe,

    quickly and with a high level of expertise.We have developed an extensive custom-

    ized service spectrum with our lifecycle

    design, which accompanies you through-

    out the entire lifecycle of your machines

    and systems. Take advantage of the per-

    sonal interaction and flexibility we offer

    in our practically oriented seminars.

    We carry out customer-specific trainings

    either at your location or at our sales and

    service locations.

    You can find additional information aboutKraussMaffei at: www.kraussmaffei.comKraussMaffei GroupComprehensive expertise

    Unique selling proposition Technology3

    The KraussMaffei Group is the only pro-

    vider in the world to possess the essen-

    tial machine technologies for plastics and

    rubber processing with its KraussMaffei,

    KraussMaffei Berstorff and Netstal

    brands: Injection Molding Machinery,

    Automation, Reaction Process Machinery

    and Extrusion Technology.

    The group is represented internationally

    with more than 30 subsidiaries and over

    ten production plants as well as about

    570 commercial and service partners.

    This is what makes us your highly skilled

    and integrated partner. Use our com-

    prehensive and unique expertise in the

    industry.

    You can find additional information at:www.kraussmaffeigroup.com

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    .1stedition08/13.

    RPM

    474BR08/2013ENKraussMaffeireservestherighttomaketechnicalchangesPrintedintheFederal

    RepublicofGermany.From pouring and foam-molding to backfoaming

    KraussMaffei makes molds for creating the perfect

    parts every time. Molds for open or closed pouring are

    made of steel or aluminum and/or with a polymer sur-

    face if required. Our molds are engineered as custom

    tools for specific applications and ensure process-

    specific heating. The molds have demolding concepts

    for non-damaging demolding, are fitted with product-

    specific seal systems and come with wear-resistant

    surfaces where necessary. This means that process,

    machinery, mold carriers and molds are perfectly

    matched.

    Foam molds for perfect partsThe right mold for every application