gas-assisted injection...

IMT

Gas-assisted Injection Molding

Airmould®

Airmould Contour®

Fields of applicationMachines and equipment

IMT


Content

1. Why do you need gas-assisted injection molding?

1.1 Airmould®

1.1.1 Application

1.1.2 Processes for gas injection

1.2 Airmould Contour®

2. What equipment do we need for gas- and water-assisted injection molding?

Gas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT



Fields of applicatonAdvantages for the molderTypical moldingsA process to resolve molding problems

Why do we need gas-assisted injection Molding?Gas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Gas-assisted injection molding

Gas-assisted processes:

1. Gas distributed in melt to form a cell structure: Structural foam processes

2. Gas used to form hollow sections: Internal gas injection technology

3. Gas injected between melt and cavity: External gas injection technology



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Why?

Improvement of part qualityNo sink marksNo or low warpingLower clamping forcesShorter cycle timesWeight saving




Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT








Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Structural Foam Technology

Low pressure structural foam:

compact skin

foamed core




Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Telephone kioskWeight: 60 kg Wall thickness: 6-8 mmPlastic: PC with 5 % glassfiber

reinforcement


Structural Foam Technology



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Multicomponent Injection Molding


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT








Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Gas-assisted Injection MoldingInternal gas pressure:Airmould®

Gas-assisted Injection Molding:External gas pressure:Airmould Contour®



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Content


1.1 Airmould®

1.1.1 Application





Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT






Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Some advantages:

Improvement of surface qualityNo sink marksNo or reduced warpageReduction of clamping forcesReduction of cycle timesPolymer and weight saving up to 50%

Why Airmould® ?



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Principle of mold cavity filling with Airmould®

Airmould®



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Thick wall grab handle, PA 12, Reduction of cycle time by 60% with Airmould®

Airmould®



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Content


1.1 Airmould®

1.1.1 Application





Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Because of different polymer and gas viscosities, moldings for gas assist need to meet specific design criteria.

Therefore suitable products have been distinguished in 4 groups of differing designs:

Rod shaped moldingsPanel shaped moldingsPanel shaped moldings with increased wall sectionsProblem moldings.

Airmould®


Moldings suitable for Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

1. Rod shaped moldings

Grab handle, ABS

Weight reduction: 30 % No sink marks


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Rod shaped moldings

Handle for refrigerator, ABS,

One single production step withAirmould®

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Rod shaped moldings

Lawn mawerhandle, PP


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Seat adjustment lever for gardenchair, PP- GF


Application

Processes

AirmouldContour®

Modular system

Airmould®

Rod shaped moldings

IMT


Airmould®

Rod shaped moldings

Steering wheel for pedal car, PP


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Rod shaped moldings

Gearshift lever for pedal car, PP


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Exterior door handle, PA 6 with 30 % GF

Weight reduction 20 %,Cycle time reduction 50 %


Application

Processes

AirmouldContour®

Modular system

Airmould®

Rod shaped moldings

IMT


Airmould®

Rod shaped moldings

Exterior door handle unit for car, Handle: Airmould®, PA GF 20


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Door handle,ABS

No sink marksNo warpageWeight reduction


Application

Processes

AirmouldContour®

Modular system

Airmould®

Rod shaped moldings

IMT


Airmould®

2. Panel shaped moldings

Garden table top:1500 x 900 mm

High rigidity and low warpingClamping force reduction of 60 % to 10.000 kN by using Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Panel shaped moldings

Rotating plate for kitchen furniture, PP

High rigidity by means of gas channels with high ribs


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

3. Panel shaped moldings with increased wall sections

Internal door handle, PP

Wall thickness from 2 to 12 mm

No sink marks with Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Door handle in PP, wall thickness 2.5 mm,wall thickness 20 mm in grab handle section

Panel shaped moldings with increased wall sections



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®


Interior door cover,PP

No sink marks• No warping


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Panel shaped moldings withincreased wall sections

Car side trims, ABS


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®


End piece of side trim for car,ABS

No sink marks


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®


weight saving for handle no sink marks in housing because of gas injection, gas is injected at 3 different locations

Exterior door handle unit with handle, PA-GF


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Gas- assisited Injection molding

Airmould®


Rear view mirrors in ABS, painted



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®


Truck intake air filter housing,PA with 30 % GF

Increased rigidity by means of gas channels using Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®


Industrial vacuum cleaner housingin ABS

increased rigidity with Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Frontend for truck,PC-PBT-blend

No warpageNo sink marksHigh rigidity


Application

Processes

AirmouldContour®

Modular system

Airmould®


IMT


Airmould®

Interior door handle and handle unitfor car, Handle: Airmould®, PA GF 20 Metallised


Application

Processes

AirmouldContour®

Modular system

Airmould®


IMT


Airmould®

Thin tube with ball, PP, tubediameter 2 mm

Weight compact: 1.4 g,Weight with Airmould®: 0,6 g


Application

Processes

AirmouldContour®

Modular system

Airmould®


IMT


Airmould®

4. Problem moldings

Washing machine front cover in ABS

Right: Warpage with conventionalinjection molding

Left: no warpage with Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Problem moldings

Left: gas injection at 2 locations by means of gas injection modules

Right: no sink marks even opposite mounting bosses

Front cover for washing machine, ABSGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Problem moldings

No sink marks using gas injection in the 4 corners

Monitor front, mod. PPEGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Problem moldings

Flatness +- 0.5 mmwas achieved by using Airmould®

U-shape border with ribs, PPEGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Problem moldings

No warping and better dimensional stability with Airmould®

Cover for car radioGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Problem moldings

Connector handle, PP

No sink marks oppositeto mounting bossesusing Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Content


1.1 Airmould®

1.1.1 Application





Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Gas injection molding

Airmould®

1. Short-Shot Process

2. Full-ShotProcess

3. Overflow Process

4. Back to Screw Process

5. Retractable Core Process


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Short-Shot Process

Short filling of the mold,complete filling by means of the gas

GasPlasticMold


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Short-Shot Process

Handle, PPWeight reduction 50 %


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmold®

Lever, PA 6 with 20 % GF,

Weight reduction 15 %, Cycle time reduction 35 %

Short-Shot ProcessGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Grab handle fortable barbecue,PA-GF

Weight reduction25 %

Short-Shot ProcessGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Short-Shot Process

Grab handle, ABS

Thick handle section, thin mounting section,no sink marks


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Short-Shot Process

Folding cjairs for the OlympicStadium in Sydney, consisting of seat, back and arm rests


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Short-Shot Process

Olympic Stadium in Sydney, equipped with Airmould® chairs


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Full-Shot Process

Complete filling of the mold, gas injection for shrinkagecompensation

Gas PlasticMoldGas injection


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Car speaker housingNo sink marks in thick sections

Full-Shot ProcessGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Short-Shot Process

TrayNo sink marks at thick sections


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Gas- asssisted Injection molding

Airmould®

Overflow Process

Complete filling of the mold,expelling plastic into overflow cavityby means of the gas

GasPlasticMoldGas injection


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Exterior door handle,PA 6 with 30% GF

Overflow ProcessGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Gas- asssisted Injection molding

Airmould®

Back to Screw Process

Complete filling of the moldpushing plastic back to screw bymeans of the gas

GasPlasticMoldGas injection


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Retractable Core Process

Core forward: complete filling with plasticCore retraction and gas injection

GasPlasticMold

Gas injectionRetractable coreHydraulics


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Bottle crateThick wall hollow handle sections

Retractable Core ProcessGas-assistedInjection M.

Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Multifoam Process

Multifoam = Co-injection and Airmould®

Start with skin material, then core material mold filling with gas

Gas Mold

Plastic: skin materialPlastic: core material


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Multifoam Process

Cross section of molding

Skin: TPECore: PPHollow section using Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Multifoam Process

Time sequence of mold filling:Co-injection:

A

B

MULTIFOAM:

A

B

Gas


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Multifoam Process

Arm rest for office chair,

Skin: PACore: PA- GFHollow section using Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Multifoam Process

Cross section of door handle

Skin: PPCore: PP foamedHollow section with Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Multifoam Process

Cross section of media duct

Skin: Polymer 1, i.e. resistantagainst chemicals

Core: Polymer 2, i.e. resistantagainst transport media

Hollow section with gas

Reference: IKV Aachen


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Content


1.1 Airmould®

1.1.1 Application





Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT








Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT






Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould Contour®

Conventional injection molding

AIRMOULD CONTOUR®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould Contour®

The Process

1. Complete filling with melt2. Injection of the gas between the melt and the mold cavity3. The gas acts as holding pressure and pushes the melt against the

opposite cavity wall.


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


The Process

Complete filling with plastic - Application of holding pressureInjection of gas between melt and cavity surfaceGas pressure is active during cooling phase and compensates forshrinkage during cooling

Gas (nitrogen)Mold

PlasticGas injection

Airmould Contour®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Fields of application for Airmould Contour®

Panel shaped moldingsPanel shaped moldings with increased wall sectionsProblem moldingsCombination of processes Airmould® und Airmould Contour®



Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT



Keys, PMMA

Airmould Contour®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT



Cover for cosmeticbox, with thick ribs,

Left: compact moldingRight: Airmould Contour®

Airmould Contour®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT



molding with ribs

Left: sink marks with conventionalinjection molding

Right: no sink marks usingAirmould Contour®

Polymer injection

Airmould Contour®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT



Key, PMMA

Airmould Contour®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould Contour®

Applications

Closure, PP Cover, PC-PBTP


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Content


1.1 Airmould®

1.1.1 Application



2. What equipment do we need for gas- and water-assisted injectionmolding?


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould® The modular system


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


The Airmould® modular system: 1. Nitrogen generators2. Pressure generators3. Gas pressure control4. Gas injection

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


1. Nitrogen generators

Nitrogen generation with membrane filtrationSpecification from 130 up to 500 Nl/minMinimum nitrogen purity 98%Chill dryer to reduce residual moistureLarge nitrogen storage accumulatorLow noise Mobile, compact design Integrated air compressor Easy maintenance

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


2. Pressure generating units

Compresses the nitrogen supplied by:

Nitrogen generator unit type SENitrogen bottlesLiquid nitrogen

One pressure generator is capable of supplying gas simultanously to several injection molding machines

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Pressure generating units seriesDE

Specification from 130 up to 500 Nl/minMax. working pressure 300 barLow noiseMobile, compact designLarge nitrogen storage accumulatorOne pressure generator iscapable of supplying gas simultanously to severalinjection molding machines

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Gas-assited Injection molding

Pressure control - two versions:

Stationary, integrated in the maschine control UNILOG B4Mobile via Airmould® interface

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Pressure control

Integrated in the machine control UNILOG B4

Up to 4 pressure control modules

For all gas injection processes

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Pressure control

Mobile Airmould® control via Airmould® interface

One Monomodule

Two Monomodules via Duplex

Mobile control unit B4 AC

Airmould® interface for all types of injection molding machines

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Pressure control

Monomodule with integratedcontrolwith manual programming devicewith all standard funtions for ex.

Impulse programManual operationDiagnostic

for up to 2 Monomodules (Duplex)

Modules can be placed close to mold to minimize gas consumption

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Pressure control


Control UNILOG B4Easy data saving

internaly 99 sets of dataexternaly on floppy disc

Languages: German and English asStandard

bar or psi

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT

Gasinjektionstechnik

Pressure control


Up to 4 pressure control modulesUp to 4 MonomodulesFor retractable gas needlesSuitable for all gas injectionprocessesOption: Hardware core pull

program

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Pressure controlMobile control unit B4 AC

User friendly setting With all standard functions e.g.

Impulse programManual operationDiagnostic

Quality controlSet- & Actual value graphicsPressure control

also for Aquamould®

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Pressure control

Pressure control module

together with stationary control

together with mobile control unit B4 AC

Modules can be placed close to mold to minimize gas consumption

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Pressure control

Quick gas pressure release valve

Recommended for:Reinforced materialsFlame retardant materialsParts with large gas volume

Reduction of:Plate-outsGas release time

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


4. Gas injection

Machine nozzle for Airmould® :

Open nozzle

Shut-off nozzle

Gas injection modules for Airmould®:

Stationary needles

Retractable needles

Airmould®


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Gas injection

Airmould® machine nozzleEasy mold designSealing is possible


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

Gas injection

Airmould® injection module

Three diameters: 3, 5 & 8 mmStandardized lengthSmall dimensionsCompact and small design Entry depth adjustableCleaning without disassembling


Application

Processes

AirmouldContour®

Modular system

Airmould®

IMT


Airmould®

The Airmould® modular system:

1. Nitrogen generators

2. Pressure generators

3. Gas pressure control

4. Gas injection


Application

Processes

AirmouldContour®

Modular system

Airmould®

Video:Production cell

IMT

Many thanks for your attention

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gas-assisted injection...

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