used for a variety of purposes.” The company, noting that it has more than

ten years of experience in the field of glass-like exterior parts, says that by combining its film and glazing technologies, it has devised a study for an innovative front module that offers solutions for many requirements of the automo- tive industry. It presented the concept simultane- ously at Fakuma and the International Suppliers Fair (IZB) for the automotive industry in Wolfsburg, Germany (home of Volkswagen).

Grilles are going “The front section of future automobiles will be characterized by three-dimensional, jointless and glass-like surfaces – the classic radiator grille will be obsolete,” says Stefan Schulten, Segment Manager Automotive in the specialty films segment at Covestro and responsible for the Europe, Middle East and Africa region. “It is not only the desire of car manufacturers to differentiate their models from the competition by designing them as individually as possible. It is also about integrating more and more functions in ever less space.” The front section can already be designed in a

variety of ways using a variety of decorated or semi-transparent films. In addition, there are, for example, lighting and signal functions such as those required for communication between an autonomous vehicle and pedestrians. One special variant is the black panel technology, in which a

According to KraussMaffei, there

are now more than 20 ColorForm systems in the field, with processors carrying out product development, and at research institutes and mould makers. He points out that the complete system is produced by KraussMaffei – the injection moulding machine and the polyure- thane processing equipment – with supervision and control of all aspects of the process via a single MC6 controller.

Lachner also points out that the

polyurethane and polyurea systems developed for the process (by Panadur for the original polyurea system and by Votteler and Ruehl for PUR systems that came later) all work without the need for an external mould release. He says this is a particularly important aspect for obtaining adoption at injection mould-

ing companies, which are generally not used to working with external mould release, unlike their counterparts in polyurethane processing. Despite the use of a reactive

polyurethane system, cycle times below the magic one-minute barrier can be obtained. Systems, both for

special Makrofol polycarbonate film with a light source behind it is illuminated. When switched off, passers-by see only a matt, black surface. The structure of the front module prototype consists of a film printed with a colourful motif, for example the company logo, depending on custom- er requirements. This composite is then over- moulded with transparent Makrolon AG polycar- bonate using IMD or what Covestro terms film insert moulding technology (FIM). “The flat surface and the depth effect of the polycarbonate create a glass-like appearance,” it says. “Besides that, a three-dimensional effect is generated, despite the use of a flat Makrofol film.” A transparent, scratch- resistant silicone hard-coating is also applied as the outermost layer.

At specialist ink and lacquer producer Pröll, Marketing Communication Manager Stefan Zäh

Door part shows the high gloss achieved with KraussMaffei’s ColorForm technology

Clearmelt and ColorForm, can be produced with self-healing proper- ties, which means that, for example, micro-scratches incurred when a car goes through a car wash disappear shortly afterwards. Earlier this year, styrenic poly- mers major Ineos Styrolution said its Luran S KR 2864C, a type of acrylonitrile-styrene-acrylate (ASA), had been selected by an unnamed leading global car manufacturer for a windscreen A pillar body trim in the first commercial application of

this material with ColorForm. Ineos Styrolution says the grade has enhanced heat resistance and the best chemical resistance among ASA grades. ASA is already well-known for its high weather resistance – some- times being described as “outdoor ABS”.

November/December 2018 | INJECTION WORLD 19

Back-moulded HVAC front panel, unlit and back-lit


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