Today, traditional hard/soft combinations are still combinations of ABS and TPU, followed by PP and its compounds in combination with TPEs on the basis of EPDM. As the soft materials can be chemically bonded, permanent bonds can be achieved with almost all conventional thermoplastics. Well known abbreviations for soft components are, for example, TPE, TPE-U, TPE-E, SB, SEBS, SEPS and TPE-S. A decisive factor for processing on the machine and the subsequent functionality of the component is perfect preparatory work with regard to material selection, as this defines the basic structure of the bond. If this step is ignored, it is often not possible to fulfil the subsequent requirements on the component as it is then only possible to change the processing window during production by means of parameterisation. It is therefore important to look into the adhesive properties of each polymer at the outset, and to involve the raw materials and machine manufacturers when choosing the design or during the construction phase at the latest. Whereas the raw materials manufacturer is responsible for the bond requirements, the machine manufacturer can define the necessary equipment at an early stage, based on the process sequence. The advantages of this are high melt transportation speeds due to optimised nozzle geometries, flow-benefiting sprue systems, small gates and hot runners with a needle shut-off system. Problems can arise due to large cross sections – starting with the machine‘s nozzle tip –, thick sprues and gates on the component, three-platen moulds and long melt dwell time in the cylinder.
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