Multi-component | moulds and components
Belgian mouldmaker Boucherie believes its new Flexi-Cube system takes multi-component moulding process optimisation to new levels of fl exibility and performance. Chris Smith reports
Boucherie fl exes the cube
Belgian mouldmaker Boucherie has developed a new stack mould technology for production of multi-compo- nent parts that offers many of the benefi ts of cube-type systems – including the ability to handle multiple materials and to integrate cooling stations or in-mould assembly – but with the potential for faster cycle times and lower investment cost. The company – a specialist supplier of multi-compo- nent moulds for high volume production of components such as toothbrushes and razor handles – has named its new patented technology Flexi-Cube. Like conventional cube mould technology, Bouche-
rie’s Flexi-Cube system uses a stack mould arrange- ment around a central multi-faced cube element. However, while traditional systems index the centre element through 90˚ on each cycle to transport the mouldings through the various over-moulding, cooling and part removal stations, the centre element in the Boucherie design remains stationary. Parts are instead indexed via a system of servo-driven carriers that run around the perimeter of the centre element on a transport track. This arrangement has a number of advantages,
according to the company. Firstly, as the centre element does not require space to rotate, the mould opening
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stroke can be reduced – and hence cycle time can be saved. For the same reason, introduction of mould cooling fl uids and additional services such as com- pressed air is also simplifi ed as conventional fi xed couplings can be used. And the reduced inertia – the movable carriers weigh much less than a cube mould centre element – makes for a faster indexing action. However, the key benefi t in terms of optimising the
multi-component moulding process is that while a traditional cube mould indexes through four defi ned stations placed at equally spaced intervals, the Flexi- Cube system allows the carriers to be indexed indepen- dently. The company says this means individual stations can be selected and positioned as needed for function, resulting in the maximum fl exibility in mould layout. For example, it is possible to place different numbers of cavities on each parting line and even to leave an exposed side-face free of cavities altogether, if required. The fi rst Flexi-Mould production system has already been delivered to an undisclosed customer producing three-component handles. The mould is a fi ve-station 24-cavity design. A hard PP is injected in the fi rst station, the pre-moulding is cooled at the second station, a second PP component is injected at the third station, the fl exible TPE is injected at the fourth station,
Main image: The core element remains
stationary in Boucherie’s Flexi-Cube
system, which uses servo-
driven carriers running on transport
tracks to index the mouldings from one moulding
station to the next
April 2013 | INJECTION WORLD 41
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