An automotive application will be used at the fair to demonstrate the ProFoam physical foaming technique, which is particu- larly suitable for fibre-rein- forced plastics (see page 14). [...] ProFoam is characterised by a simple process sequence. The only setting re- quired is the variable “process gas pres- sure” parameter. [...] Info Lightweight construction PROCESSES In the ProFoam process, the plastic granulate is first mixed with liquid propellant in a granulate lock between the material reser- voir and material feed (photo bottom centre).
KG, based in Lohne, Germany, is a long-standing ARBURG cus- tomer and expert in the field of physical foaming. Since 2017, the ProFoam process has been in use for manufacturing lightweight parts. [...] ProFoam is particularly well-suited for technical functional parts. [...] Adapted part design can achieve weight reductions of between ten and thirty percent. Foaming with ProFoam or MuCell can achieve a further seven to twelve percent.
The physical properties of the blowing agent and foam-appropriate component and mould optimisation often enable the cycle time to be reduced, thereby ensuring cost-effective production and enabling you to get the most out of foaming. \\ FOAM INJECTION MOULDING Material-saving: physical foaming creates minute cellular structures in the part. 30% Compared to compact components, up to LIGHTER 7 8 INJECTION UNITS FOR MUCELL® 290 400 800 1300 2100 3200 4600 Screw diameter [mm] 30 40 50 60 70 80 90 A LL R O U N D ER 370 ■ − − − − − − 470 ■ ■ − − − − − 520 ■ ■ ■ − − − − 570 − ■ ■ ■ − − − 630 − − ■ ■ ■ − − 720 − − − ■ ■ ■ − 820 − − − − ■ ■ ■ 920 − − − − ■ ■ ■ Perfect interaction: modular ALLROUNDER and special MuCell® technology from Trexel Inc. 9 MuCell®process In the MuCell® process, microcellular structures are created by bringing a gaseous blowing agent to a supercrit- ical state (SCF). [...] In addition to suitable technology, foam-appropri- ate optimisation of the component and mould design is a critical element. [...] Using our powerful, customizable ALLROUNDER machines and applying our in- depth expertise, we develop the best production solution for your needs.\\ APPLICATIONS: IN PRACTICE Innovative: the semi-finished fibre matrix is heated directly in the mould, formed and overmoulded. Firmly bonded: Particle-foam Composite Injection Moulding® combines the benefits of particle foam with thermoplastics. 19 Cost-efficient: sturdy cable drive housing made using the FDC-pro- cess, dispensing with more expensive pre-compounded granulate mixture.
What lies behind the new process? With Particle-foam Composite Injection Moulding (PCIM), a polymer is injected onto a product made from particle foam. [...] A strong, permanent bond is created between the particle-foam and polymer components. This allows the typical proper- ties of particle foams such as EPP and injec-ties of particle foams such as EPP and injec-ties of particle foams such as EPP and injec tion moulding compounds such as ABS, PP or TPE to be combined in a composite part. Particle foams include materials with a variety of different characteristics.
OUR COMPANY Example: Injection moulding and foaming today: How can the efficiency of auto- mated systems be further enhanced? [...] Curing of the new PUR foam is accelerated through the heat of the moulded parts. No long curing belts or in- termediate storage are necessary. [...] During relocation of the robotic mod- ule, centrally stored ready-made sub-pro- grams can be accessed. Only mould entry needs to be set up again.
After injection, the mould opens and the component foams up. The foaming is controlled by the design of the component wall and the cooling. The foamed wall thickness is two millimetres, almost 4 times greater than what it was at the beginning of the pro- cess. The resulting skin-foam-skin structure with fine-celled foam cells of diameters be- tween five and 50 micrometres is ultimate- ly crucial for the cup’s low weight, great strength and thermal insulating properties.
On-trend: lightweight construction ProFoam is one of the innovative pro- cesses that ARBURG is advancing for the efficient production of lightweight yet strong plastic components. [...] At the Customer Center, lightweight parts were produced using the ProFoam process, for example (photos above and below). In the presentation section, experts such as Manuel Wöhrle (centre photo) provided information on current topics. [...] In his presentation on current lightweight construction trends he intro- duced Fibre Direct Compounding (FDC) and the ProFoam physical foaming tech- nique. Practical applications of both of these injection moulding processes were on show at the ARBURG Customer Center in the afternoon.
The PCR, which is available on the market, is processed by an electric two- component ALLROUNDER 630 A using the ProFoam foaming process while TPE is used as the second material. The two foamed halves of the handle are mounted in the mould and then partially overmoulded with the soft component. [...] Highlights include two-component injection moulding in combination with ProFoam foaming technology and the FIM process (Film Insert Moulding). [...] Two-component technology combined with ProFoam One highlight is the automated two- component injection moulding in combi- nation with ProFoam foaming technology.
At the Fakuma 2014, ARBURG is present- ing Particle-foam Composite Injec-ing Particle-foam Composite Injec-ing Particle-foam Composite Injec tion Moulding (PCIM) as an example of function integration, the subject of the Blue Competence initiative “There's more to plastic”, which is the focus of the Plastics and Rubber Machinery Association (KuG) within the German Machinery and Plant Manufacturers Association (VDMA). [...] “Composite parts of this kind – com- prising a foamed EPP and a moulded-on component – can then be easily integrat- ed in foamed EPP housings or panels as standard parts in a further step in order to create mechanical connections or to easily connect watertight media lines,” explains Dr. [...] The integrated thread, for example, enables screw connections for foamed automotive components or the connection of a condensation drain on foamed housings for ventilation and extraction systems.
Consequently, ARBURG has, jointly with partners, devel- injection moulding and Particle-foam Composite Injection Moulding pro- cesses, which is being presented with new or enhanced component ideas at the K 2013. - 50 mm are fed directly into the liquid melt, where they are evenly distributed. combined with organic sheet The manner in which this process reinforced thermoplastic inserts is demon- strated by ARBURG, jointly with Georg Kaufmann Formenbau AG and fpt Robotik. [...] In this manner, resilient composite parts are created, which weigh less than 300 grams at a length exceeding 500 mm. Secure bonding of foam and mould- ed parts Particle-foam Composite Injection Moulding (PCIM), which was jointly developed by Novaplast, Krallmann and ARBURG, also offers new possibilities in lightweight construction. [...] PCIM is on show as a two-component First, a particle-foam tyre is inserted into the mould, after which a plastic wheel rim is moulded onto it.
