technology | In-line compounding PHOTO: KRAUSSMAFFEI
Above and right: IMC is used for automotive parts such as technical front ends, as well as large non-auto parts like pallets
following cooperation with the University of Toronto, Krauss- Maffei began offering IMC with the Trexel Mucell physical foaming process, which the machinery maker markets within its CellForm brand of physical and chemical foaming technologies. KraussMaffei does not say
how many systems it has sold, only noting that IMC technology is in use worldwide. Most units are understood to be operating at customers in Europe, many of them making automotive parts. In principle, IMC can be used for producing and
processing various types of compounds, but today most systems are used with long fibre reinforced compounds (LFTs). Stefan Fenske, Technology Manager for IMC (and also for KraussMaffei’s FiberForm technology for production of parts by overmoulding of thermoformed “organic” sheets or tapes—typically continuous fibre reinforced polyamide), says it is best suited for produc- tion of parts with high shot weights. “The higher the shot weight, the higher the material cost saving potential,” he explains, adding that IMC also appeals to companies with requirements for special compounds.
Meeting expectations Fenske says IMC has met KraussMaffei’s expectations and believes there is considerable potential for further development, such as the process combination with physical foaming. He says KraussMaffei is working on further developments in processing of LFTs, particu- larly polyamide-based types, taking advantage of the ability of the process to incorporate in-line drying. There is also a development focus on carbon fibre processing. KraussMaffei is carrying out joint research and development with customers for special blends and
92 COMPOUNDING WORLD | October 2016
compounds, too. “A lot of institutes and universities in Germany and worldwide have an IMC to perform their own research and development. Here, customer trials are possible as well,” Fenske says. The company recently, for instance, highlighted the installation of an IMC system at the Automotive Centre Südwestfalen (ACS) in Germany, a research and knowledge transfer centre focused on alternative materials and new technologies for weight reduction in cars. So what does Fenske think has stopped rival equipment companies being successful with similar development paths? Has it been superseded by processes for direct incorporation of continuous fibres into injection moulding machines without the need for a separate compounding unit, the rise of ready-made LFT compounds, and processes such as KraussMaffei’s own FiberForm? Not the latter, at least. “The IMC has its own target
group,” Fenske says. “The main advantage is to save costs on material cost level compared to
standard injection moulding with fibre-
reinforced injection moulding material (LFT pellets). FiberForm is a technology to increase the mechanical
properties of plastic parts tremendously by the introduc- tion of an organic sheet. IMC has not been superseded by the FiberForm, or any other KraussMaffei technology, but rather fits in seamlessly in our overall technology portfolio.”
Alternative solutions Other companies have developed rival systems with varying degrees of success. Husky unveiled a system in 2006 using a compounding extruder operating discon- tinuously but, since it decided to concentrate on packaging applications for its injection moulding machines, that project has died. Husky partnered with Coperion (Coperion Werner & Pfleiderer at the time) in developing the “ILC” system, which combined a Husky Quadloc machine and Coperion ZSK70 twin screw extruder. At least one system was installed at a global Tier 1 automotive supplier. PlastiComp, a pioneer in LFT technology, launched Pushtrusion direct inline compounding and moulding of LFTs in 2006. This combined its well-known pultrusion- type process for impregnating continuous rovings with a thermoplastic directly with a standard injection moulding machine. At the time, PlastiComp said Engel would make Pushtrusion technology available as an option on its Combi series injection moulding machines
www.compoundingworld.com
PHOTO: KRAUSSMAFFEI
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82 |
Page 83 |
Page 84 |
Page 85 |
Page 86 |
Page 87 |
Page 88 |
Page 89 |
Page 90 |
Page 91 |
Page 92 |
Page 93 |
Page 94 |
Page 95 |
Page 96 |
Page 97 |
Page 98 |
Page 99 |
Page 100 |
Page 101 |
Page 102 |
Page 103 |
Page 104 |
Page 105 |
Page 106 |
Page 107 |
Page 108 |
Page 109 |
Page 110 |
Page 111 |
Page 112