Battenfeld of America Inc. (Booth S1802) is showing all-electric molding, micromolding, in-mold trimming and decorating of a car part and the IMPmore process for injection compression molding car windshields out of polycarbonate.
Battenfeld also is rolling out a special high-speed model of its HM press, called the Advantage.
The challenges with PC windshields is making them at high volumes but with low mold-in stress, to avoid distortion, making the window scratch-resistant, like glass. This week in Chicago, Battenfeld is showing the solution: partnering with German mold maker Summerer Technologies and Exatec, a joint venture of GE Plastics and Bayer Corp.
Exatec developed a plasma coating to improve scratch resistance.
Battenfeld is molding windshields on a two-platen, 2,200-ton HM press. The press has retractable tie-bars that pull back when the mold opens, allowing an ABB articulating robot to reach in to remove the windshield.
The other automotive application, called IMCmore, is automated trimming and decorating of a back-molded textile part - a B pillar with a molded-on, sealed lip. A Battenfeld HM press molds the multicomponent part, with injection units set up in an L configuration.
First, the textile is fed from a roll and cut to size with a laser. A Battenfeld Unirob robot places the material inside the mold. The press overmolds the textile with polypropylene, excess material is trimmed inside the mold and finally a thermoplastic elastomer sealing lip is molded onto the pillar.
Battenfeld displayed IMCmore at the K 2001 show in Germany.
Also at NPE, Battenfeld wants to gain the Advantage in thin-wall molding. The new Advantage version of its HM press boasts a 50 percent higher injection rate than standard HMs. The 176-ton press, equipped with an SER 10-15 side-entry robot, is whipping out PC mini-disc cases. The robot moves in and out of the four-cavity mold in just one-tenth of a second.
Battenfeld also is showing the EM all-electric press, molding a PC lamp socket. The melt is injected through a tunnel gate into the two mold cavities. The maker of the sliding split mold is Zumtobel Staff Werkzeugbau of Dornbirn, Austria.
The company has expanded the EM press to 176 tons of clamping force.
In micromolding news, a Microsystem 50 press is molding a subconnector housing for the electronics industry that is smaller that a match head. The cycle time is just 2.5 seconds, including the time required for handling and sprue picking.
The company also is running a vertical-clamp press to insert mold an initiator switch for an air bag. Battenfeld is partnering with a customer, LifeSparc Inc., to show the technology. LifeSparc of Hollister, Calif., molded more than 12 million of the air-bag initiators in 2002.
Finally, want to buy a machine today, cash and carry? Visit the three-level cash-and-carry tower that holds two standardized presses and one robot for immediate delivery, at a pre-set price. It's called the Performance Enhancement Package.
Just don't forget to check the press at O'Hare - don't try to carry it on.