automotive | Interior/exterior
Right: Engel’s DecoJect in-mould graining
process makes it easy to
change from one decorative finish to another
and also structural brackets – that provide the required high surface aesthetic and also the necessary high strength and vibration resistance. Global Auto Segment Leader Phillip Jeszke says some Japanese car makers are already using Vydyne grades with levels of rein- forcement between 30 and 50% for producing these brackets. Jeszke also cites applications for glass
reinforced Vydyne compounds in interior applications such as seat shells (in production with Hyundai in the US) and gear shift housings. “There are lots of tough conditions to meet for materi- als used in these parts,” he says, citing creep resist- ance and heat resistance in particular. “Tight tolerances call for high consistency in the material, which means things like constant molecular weight as well as levels of glass incorporation for example. At our polymer plant, we can get a very tight window on viscosity, which also leads to more even shot sizes and cycle times.” Albis says its Alcom MS PA66+6I/X 2050 - MS stands
Below: This detail image shows the high quality grain reproduction achievable from the DecoJect process
for Modified Surface - is a modified polyamide 66 developed for fascias, trims and other surfaces “with an aesthetically pleasing appearance in the passenger compartment for concealed as well as visible applica- tions.” The compounder says fibres and fillers do not show through on the surface of parts moulded using the grade. “This means it is no longer necessary to cover or disguise visible surfaces…time-consuming tasks such as painting or the use of other coverings can be reduced or eliminated completely.” The high percentage of glass fibres (50%) makes this grade extremely rigid and imparts high dimensional stability, but flow is still said to be good.
Integrated production K2016 provided the major injection machinery makers the chance to show off their latest integrated systems for automotive part production. Engel, as an example, demonstrated its new DecoJect process – result of an
18-month cooperation involving foil producer Benecke- Kaliko (which owns the DecoJect name) and others - manufacturing a prototype upper door panel. Unlike some other in-mould decoration processes, in
the DecoJect process the backing film becomes an integral part of the part. Furthermore, surface texture is applied to the film in the injection mould. This is achieved by first unrolling the film across the mould, heating it using an infrared system mounted on a robot arm, and then vacuum forming it into place, during which it picks up every last detail from the mould surface. PP (from Borealis in the K exhibit) is then injec- tion moulded behind it and, as it completely covered, the PP does not need to be coloured. The test mould being used in the project was built by
Georg Kaufmann Formenbau, using a nickel shell made by Galvanoform. “We can now make moulds with nickel shells for applying the grain that can also withstand injection moulding pressures of up to 300 bar,” says Michael Fischer, Technologies Sales Manager at Engel. “In the past, this was a no-no, because the nickel shell would break under that sort of pressure.” The technology makes use of Trexel’s MuCell
physical foaming technology which, apart from reducing part weight, also enables lower injection pressures than more conventional moulding. Advanced injection moulding control ensures the mould is not over-packed, while a sophisticated servo-controlled FLEXflow hot runner system from HRSflow manages filling. “Also very important is the pre-heating of the film,” Fischer says. “Temperature control is very important. The film is just 0.3 mm thick, so it could easily burn.” The film used is based on a TPO with a polyurethane lacquer that is capable (in conjunction with the thermoforming process) of simulating a wide range of finishes, including leather and textiles. No commercial projects have been confirmed for the
process, but Fischer says he is very hopeful and adds that Engel has already held discussions with various
22 INJECTION WORLD | November/December 2016
www.injectionworld.com
PHOTO: CHRIS SMITH
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