Multi-Material Injection Moulding (Rapra Review Reports)

Report 145

ISSN: 0889-3144

Multi-Material Injection Moulding

V. Goodship and J.C. Love

Volume 13, Number 1, 2002

Rapra Review Reports Expert overviews covering the science and technology of rubber and plastics

RAPRA REVIEW REPORTS A Rapra Review Report comprises three sections, as follows: 1. A commissioned expert review, discussing a key topic of current interest, and referring to the References and Abstracts section. Reference numbers in brackets refer to item numbers from the References and Abstracts section. Where it has been necessary for completeness to cite sources outside the scope of the Rapra Abstracts database, these are listed at the end of the review, and cited in the text as a.1, a.2, etc. 2. A comprehensive References and Abstracts section, resulting from a search of the Rapra Abstracts database. The format of the abstracts is outlined in the sample record below. 3. An index to the References and Abstracts section, derived from the indexing terms which are added to the abstracts records on the database to aid retrieval.

Source of original article Title

Item 1 Macromolecules

33, No.6, 21st March 2000, p.2171-83 EFFECT OF THERMAL HISTORY ON THE RHEOLOGICAL BEHAVIOR OF THERMOPLASTIC POLYURETHANES Pil Joong Yoon; Chang Dae Han Akron,University The effect of thermal history on the rheological behaviour of ester- and ether-based commercial thermoplastic PUs (Estane 5701, 5707 and 5714 from B.F.Goodrich) was investigated. It was found that the injection moulding temp. used for specimen preparation had a marked effect on the variations of dynamic storage and loss moduli of specimens with time observed during isothermal annealing. Analysis of FTIR spectra indicated that variations in hydrogen bonding with time during isothermal annealing very much resembled variations of dynamic storage modulus with time during isothermal annealing. Isochronal dynamic temp. sweep experiments indicated that the thermoplastic PUs exhibited a hysteresis effect in the heating and cooling processes. It was concluded that the microphase separation transition or order-disorder transition in thermoplastic PUs could not be determined from the isochronal dynamic temp. sweep experiment. The plots of log dynamic storage modulus versus log loss modulus varied with temp. over the entire range of temps. (110-190C) investigated. 57 refs.

Location

GOODRICH B.F. USA

Authors and affiliation

Abstract

Companies or organisations mentioned

Accession no.771897

DOCUMENT DELIVERY SERVICE Almost all of the documents which are listed in the References and Abstracts section are available in full text form, as photocopies or pdf files from Rapra Technology Ltd’s Document Delivery Service. Documents can be delivered by a variety of methods, including email, post or fax. Customers may pay for individual copies at the time of ordering by credit card or alternatively open up a deposit account. See the back of this report for further information. Please contact the Document Delivery Department for availability, current prices and delivery methods. Document Delivery Department Rapra Technology Limited, Shawbury, Shrewsbury, Shropshire SY4 4NR, United Kingdom Telephone: +44 (0)1939 250383 Fax: +44 (0)1939 251118 Email: [email protected]

RAPRA REVIEW REPORTS VOLUME 13 Series Editor Dr. S. Humphreys, Rapra Technology Limited Rapra Review Reports comprise a unique source of polymer-related information with useful overviews accompanied by abstracts from hundreds of relevant documents. A Rapra Review Report is an excellent starting point to improve subject knowledge in key areas. Subscribers to this series build up a bank of information over each year, forming a small library at a very reasonable price. This series would be an asset to corporate libraries, academic institutions and research associations with an interest in polymer science. Twelve reports are published in each volume and these can be purchased individually or on a subscription basis. Format: Soft-backed, 297 x 210 mm, ISSN: 0889-3144 Order individual published Rapra Review Reports (see the following pages for a list of available titles), or purchase a subscription to Volume 13 (12 issues).

ORDER FORM Title of Publication

Price £/$/€

I would like to order the following Rapra Review Report(s) at £80 / US$120 / €136 each Report Number(s) ................................................................................................ (please state quantity if more than one) Please add postage at the following rates: UK £5 total, Overseas £7 / US$11 / €10 per item Subtotal: I would like to order ................ subscription(s) to Volume 13 of the Rapra Review Report Series at £630 / US$882 / €1071 each Please add postage at the following rates: UK £35 total, Overseas £65 / US$110 / €110 per subscription Total Order Value:

All prices are subject to change and orders will be charged at the price indicated on www.polymer-books.com on the date of processing

❑ Remittance enclosed ❑ Please invoice my company ❑ Please charge my credit card

(Please make cheques payable to Rapra Technology Ltd. in £ Sterling/US$/Euros via UK banks only or make payment direct to Account No: 05625025, Sortcode: 55-50-05, National Westminster Bank Plc, 8 Mardol Head, Shrewsbury, Shropshire, SY1 1HE, UK)

American Express / Visa / Mastercard (delete as appropriate)

IMPORTANT - Value Added Tax (VAT) The above prices do not include VAT. Customers in EU member countries may be liable to pay VAT if their Registration Number is not supplied. Please enter your EU Registration Number (VAT - BTW - IVA - TVA - MWST - MOMS - FPA) below:

Card Number: VAT Number:

Signature: ______________________ Exp. date: _________________

Full Name: ________________________________________________

Issuing Bank: ______________________________________________

Company: _________________________________________________

_________________________________________________________

Job Function: ______________________________________________

Cardholders Name (as on card): _______________________________

Delivery Address (if different from Cardholder's Address): _________

Cardholders Address: ________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

Postcode: ______________________ Country: __________________

_________________________________________________________

Telephone: _____________________ Fax: ______________________

Postcode: ______________________ Country: __________________ Telephone: _____________________ Fax: ______________________

If you would like to receive regular electronic updates informing you of new titles and offers please enter your E-mail address below.

Company PO#: _____________________________________________

E-mail: ___________________________________________________

Please Return to:

Publications Sales, Rapra Technology Limited Shawbury, Shrewsbury, Shropshire SY4 4NR, United Kingdom

Tel. +44 (0)1939 250383 Fax: +44 (0)1939 251118 E-mail: [email protected]

www.rapra.net

Previous Titles Still Available Volume 1

Volume 4

Report 3

Advanced Composites, D.K. Thomas, RAE, Farnborough.

Report 37

Report 4

Liquid Crystal Polymers, M.K. Cox, ICI, Wilton.

Polymers in Aerospace Applications, W.W. Wright, University of Surrey.

Report 5

CAD/CAM in the Polymer Industry, N.W. Sandland and M.J. Sebborn, Cambridge Applied Technology.

Report 39

Polymers in Chemically Resistant Applications, D. Cattell, Cattell Consultancy Services.

Report 8

Engineering Thermoplastics, I.T. Barrie, Consultant.

Report 41

Failure of Plastics, S. Turner, Queen Mary College.

Report 11

Communications Applications of Polymers, R. Spratling, British Telecom.

Report 42

Polycarbonates, R. Pakull, U. Grigo, D. Freitag, Bayer AG.

Report 12

Process Control in the Plastics Industry, R.F. Evans, Engelmann & Buckham Ancillaries.

Report 43

Polymeric Materials from Renewable Resources, J.M. Methven, UMIST.

Report 44

Flammability and Flame Retardants in Plastics, J. Green, FMC Corp.

Volume 2 Report 13

Injection Moulding of Engineering Thermoplastics, A.F. Whelan, London School of Polymer Technology.

Report 45

Composites - Tooling and Component Processing, N.G. Brain, Tooltex.

Report 14

Polymers and Their Uses in the Sports and Leisure Industries, A.L. Cox and R.P. Brown, Rapra Technology Ltd.

Report 46

Quality Today in Polymer Processing, S.H. Coulson, J.A. Cousans, Exxon Chemical International Marketing.

Report 47

Report 15

Polyurethane, Materials, Processing and Applications, G. Woods, Consultant.

Chemical Analysis of Polymers, G. Lawson, Leicester Polytechnic.

Report 16

Polyetheretherketone, D.J. Kemmish, ICI, Wilton.

Report 17

Extrusion, G.M. Gale, Rapra Technology Ltd.

Report 49

Report 18

Agricultural and Horticultural Applications of Polymers, J.C. Garnaud, International Committee for Plastics in Agriculture.

Blends and Alloys of Engineering Thermoplastics, H.T. van de Grampel, General Electric Plastics BV.

Report 50

Report 19

Recycling and Disposal of Plastics Packaging, R.C. Fox, Plas/Tech Ltd.

Automotive Applications of Polymers II, A.N.A. Elliott, Consultant.

Report 51

Report 20

Pultrusion, L. Hollaway, University of Surrey.

Biomedical Applications of Polymers, C.G. Gebelein, Youngstown State University / Florida Atlantic University.

Report 21

Materials Handling in the Polymer Industry, H. Hardy, Chronos Richardson Ltd.

Report 52

Polymer Supported Chemical Reactions, P. Hodge, University of Manchester.

Report 22

Electronics Applications of Polymers, M.T.Goosey, Plessey Research (Caswell) Ltd.

Report 53

Weathering of Polymers, S.M. Halliwell, Building Research Establishment.

Report 23

Offshore Applications of Polymers, J.W.Brockbank, Avon Industrial Polymers Ltd.

Report 54

Health and Safety in the Rubber Industry, A.R. Nutt, Arnold Nutt & Co. and J. Wade.

Report 24

Recent Developments in Materials for Food Packaging, R.A. Roberts, Pira Packaging Division.

Report 55

Computer Modelling of Polymer Processing, E. Andreassen, Å. Larsen and E.L. Hinrichsen, Senter for Industriforskning, Norway.

Volume 3

Report 56

Plastics in High Temperature Applications, J. Maxwell, Consultant.

Report 25

Report 57

Joining of Plastics, K.W. Allen, City University.

Report 58

Physical Testing of Rubber, R.P. Brown, Rapra Technology Ltd.

Report 59

Polyimides - Materials, Processing and Applications, A.J. Kirby, Du Pont (U.K.) Ltd. Physical Testing of Thermoplastics, S.W. Hawley, Rapra Technology Ltd.

Foams and Blowing Agents, J.M. Methven, Cellcom Technology Associates.

Volume 5

Report 26

Polymers and Structural Composites in Civil Engineering, L. Hollaway, University of Surrey.

Report 27

Injection Moulding of Rubber, M.A. Wheelans, Consultant.

Report 28

Adhesives for Structural and Engineering Applications, C. O’Reilly, Loctite (Ireland) Ltd.

Report 60

Report 29

Polymers in Marine Applications, C.F.Britton, Corrosion Monitoring Consultancy.

Volume 6

Report 30

Non-destructive Testing of Polymers, W.N. Reynolds, National NDT Centre, Harwell.

Report 61

Food Contact Polymeric Materials, J.A. Sidwell, Rapra Technology Ltd.

Report 31

Silicone Rubbers, B.R. Trego and H.W.Winnan, Dow Corning Ltd.

Report 62

Coextrusion, D. Djordjevic, Klöckner ER-WE-PA GmbH.

Report 63

Conductive Polymers II, R.H. Friend, University of Cambridge, Cavendish Laboratory.

Report 64

Designing with Plastics, P.R. Lewis, The Open University. Decorating and Coating of Plastics, P.J. Robinson, International Automotive Design.

Report 32

Fluoroelastomers - Properties and Applications, D. Cook and M. Lynn, 3M United Kingdom Plc and 3M Belgium SA.

Report 33

Polyamides, R.S. Williams and T. Daniels, T & N Technology Ltd. and BIP Chemicals Ltd.

Report 65

Report 34

Extrusion of Rubber, J.G.A. Lovegrove, Nova Petrochemicals Inc.

Report 66

Report 35

Polymers in Household Electrical Goods, D.Alvey, Hotpoint Ltd.

Reinforced Thermoplastics - Composition, Processing and Applications, P.G. Kelleher, New Jersey Polymer Extension Center at Stevens Institute of Technology.

Report 67

Report 36

Developments in Additives to Meet Health and Environmental Concerns, M.J. Forrest, Rapra Technology Ltd.

Plastics in Thermal and Acoustic Building Insulation, V.L. Kefford, MRM Engineering Consultancy.

Report 68

Cure Assessment by Physical and Chemical Techniques, B.G. Willoughby, Rapra Technology Ltd.

Report 69

Toxicity of Plastics and Rubber in Fire, P.J. Fardell, Building Research Establishment, Fire Research Station.

Report 70

Acrylonitrile-Butadiene-Styrene Polymers, M.E. Adams, D.J. Buckley, R.E. Colborn, W.P. England and D.N. Schissel, General Electric Corporate Research and Development Center.

Report 71

Rotational Moulding, R.J. Crawford, The Queen’s University of Belfast.

Report 72

Advances in Injection Moulding, C.A. Maier, Econology Ltd.

Report 94

Compressive Behaviour of Composites, C. Soutis, Imperial College of Science, Technology and Medicine.

Report 95

Thermal Analysis of Polymers, M. P. Sepe, Dickten & Masch Manufacturing Co.

Report 96

Polymeric Seals and Sealing Technology, J.A. Hickman, St Clair (Polymers) Ltd.

Volume 9 Report 97

Rubber Compounding Ingredients - Need, Theory and Innovation, Part II: Processing, Bonding, Fire Retardants, C. Hepburn, University of Ulster.

Report 98

Advances in Biodegradable Polymers, G.F. Moore & S.M. Saunders, Rapra Technology Ltd.

Report 99

Recycling of Rubber, H.J. Manuel and W. Dierkes, Vredestein Rubber Recycling B.V.

Volume 7 Report 73

Reactive Processing of Polymers, M.W.R. Brown, P.D. Coates and A.F. Johnson, IRC in Polymer Science and Technology, University of Bradford.

Report 74

Speciality Rubbers, J.A. Brydson.

Report 75

Plastics and the Environment, I. Boustead, Boustead Consulting Ltd.

Report 100 Photoinitiated Polymerisation - Theory and Applications, J.P. Fouassier, Ecole Nationale Supérieure de Chimie, Mulhouse.

Report 76

Polymeric Precursors for Ceramic Materials, R.C.P. Cubbon.

Report 101 Solvent-Free Adhesives, T.E. Rolando, H.B. Fuller Company.

Report 77

Advances in Tyre Mechanics, R.A. Ridha, M. Theves, Goodyear Technical Center.

Report 102 Plastics in Pressure Pipes, T. Stafford, Rapra Technology Ltd.

Report 78

PVC - Compounds, Processing and Applications, J.Leadbitter, J.A. Day, J.L. Ryan, Hydro Polymers Ltd.

Report 103

Report 79

Rubber Compounding Ingredients - Need, Theory and Innovation, Part I: Vulcanising Systems, Antidegradants and Particulate Fillers for General Purpose Rubbers, C. Hepburn, University of Ulster.

Report 80

Anti-Corrosion Polymers: PEEK, PEKK and Other Polyaryls, G. Pritchard, Kingston University.

Report 81

Thermoplastic Elastomers - Properties and Applications, J.A. Brydson.

Report 82

Advances in Blow Moulding Process Optimization, Andres Garcia-Rejon,Industrial Materials Institute, National Research Council Canada.

Report 83

Molecular Weight Characterisation of Synthetic Polymers, S.R. Holding and E. Meehan, Rapra Technology Ltd. and Polymer Laboratories Ltd.

Report 84

Rheology and its Role in Plastics Processing, P. Prentice, The Nottingham Trent University.

Gas Assisted Moulding, T.C. Pearson, Gas Injection Ltd.

Report 104 Plastics Profile Extrusion, R.J. Kent, Tangram Technology Ltd. Report 105 Rubber Extrusion Theory and Development, B.G. Crowther. Report 106 Properties and Applications of Elastomeric Polysulfides, T.C.P. Lee, Oxford Brookes University. Report 107 High Performance Polymer Fibres, P.R. Lewis, The Open University. Report 108 Chemical Characterisation of Polyurethanes, M.J. Forrest, Rapra Technology Ltd.

Volume 10 Report 109 Rubber Injection Moulding - A Practical Guide, J.A. Lindsay. Report 110 Long-Term and Accelerated Ageing Tests on Rubbers, R.P. Brown, M.J. Forrest and G. Soulagnet, Rapra Technology Ltd.

Volume 8

Report 111

Polymer Product Failure, P.R. Lewis, The Open University.

Report 85

Ring Opening Polymerisation, N. Spassky, Université Pierre et Marie Curie.

Report 112 Polystyrene - Synthesis, Production and Applications, J.R. Wünsch, BASF AG.

Report 86

High Performance Engineering Plastics, D.J. Kemmish, Victrex Ltd.

Report 113 Rubber-Modified Thermoplastics, H. Keskkula, University of Texas at Austin.

Report 87

Rubber to Metal Bonding, B.G. Crowther, Rapra Technology Ltd.

Report 114 Developments in Polyacetylene - Nanopolyacetylene, V.M. Kobryanskii, Russian Academy of Sciences.

Report 88

Plasticisers - Selection, Applications and Implications, A.S. Wilson.

Report 115 Metallocene-Catalysed Polymerisation, W. Kaminsky, University of Hamburg.

Report 89

Polymer Membranes - Materials, Structures and Separation Performance, T. deV. Naylor, The Smart Chemical Company.

Report 116 Compounding in Co-rotating Twin-Screw Extruders, Y. Wang, Tunghai University.

Report 90

Rubber Mixing, P.R. Wood.

Report 117 Rapid Prototyping, Tooling and Manufacturing, R.J.M. Hague and P.E. Reeves, Edward Mackenzie Consulting.

Report 91

Recent Developments in Epoxy Resins, I. Hamerton, University of Surrey.

Report 118 Liquid Crystal Polymers - Synthesis, Properties and Applications, D. Coates, CRL Ltd.

Report 92

Continuous Vulcanisation of Elastomer Profiles, A. Hill, Meteor Gummiwerke.

Report 119 Rubbers in Contact with Food, M.J. Forrest and J.A. Sidwell, Rapra Technology Ltd.

Report 93

Advances in Thermoforming, J.L. Throne, Sherwood Technologies Inc.

Report 120 Electronics Applications of Polymers II, M.T. Goosey, Shipley Ronal.

Volume 11 Report 121 Polyamides as Engineering Thermoplastic Materials, I.B. Page, BIP Ltd. Report 122 Flexible Packaging - Adhesives, Coatings and Processes, T.E. Rolando, H.B. Fuller Company. Report 123 Polymer Blends, L.A. Utracki, National Research Council Canada. Report 124 Sorting of Waste Plastics for Recycling, R.D. Pascoe, University of Exeter. Report 125 Structural Studies of Polymers by Solution NMR, H.N. Cheng, Hercules Incorporated. Report 126 Composites for Automotive Applications, C.D. Rudd, University of Nottingham. Report 127 Polymers in Medical Applications, B.J. Lambert and F.-W. Tang, Guidant Corp., and W.J. Rogers, Consultant. Report 128 Solid State NMR of Polymers, P.A. Mirau, Lucent Technologies. Report 129 Failure of Polymer Products Due to Photo-oxidation, D.C. Wright. Report 130 Failure of Polymer Products Due to Chemical Attack, D.C. Wright. Report 131 Failure of Polymer Products Due to Thermo-oxidation, D.C. Wright. Report 132 Stabilisers for Polyolefins, C. Kröhnke and F. Werner, Clariant Huningue SA.

Volume 12 Report 133 Advances in Automation for Plastics Injection Moulding, J. Mallon, Yushin Inc. Report 134 Infrared and Raman Spectroscopy of Polymers, J.L. Koenig, Case Western Reserve University. Report 135 Polymers in Sport and Leisure, R.P. Brown. Report 136 Radiation Curing, R.S. Davidson, DavRad Services. Report 137 Silicone Elastomers, P. Jerschow, Wacker-Chemie GmbH. Report 138 Health and Safety in the Rubber Industry, N. Chaiear, Khon Kaen University. Report 139 Rubber Analysis - Polymers, Compounds and Products, M.J. Forrest, Rapra Technology Ltd. Report 140 Tyre Compounding for Improved Performance, M.S. Evans, Kumho European Technical Centre. Report 141 Particulate Fillers for Polymers, Professor R.N. Rothon, Rothon Consultants and Manchester Metropolitan University. Report 142 Blowing Agents for Polyurethane Foams, S.N. Singh, Huntsman Polyurethanes. Report 143 Adhesion and Bonding to Polyolefins, D.M. Brewis and I. Mathieson, Institute of Surface Science & Technology, Loughborough University. Report 144 Rubber Curing Systems, R.N. Datta, Flexsys BV.

Multi-Material Injection Moulding V. Goodship and J.C. Love (The University of Warwick)

ISBN 1-85957-327-4

Multi-Material Injection Moulding

Contents 1.

2.

3.

4.

5.

Introduction .............................................................................................................................................. 3 1.1

Multi-Component Moulding ........................................................................................................... 3 1.1.1 Co-Injection Moulding ....................................................................................................... 3 1.1.2 Bi-Injection Moulding ........................................................................................................ 3 1.1.3 Interval Injection Moulding ............................................................................................... 4

1.2

Multi-Shot Moulding ...................................................................................................................... 1.2.1 Transfer ............................................................................................................................... 1.2.2 Core Back ........................................................................................................................... 1.2.3 Rotating Tool ......................................................................................................................

1.3

Over-Moulding ............................................................................................................................... 4

1.4

Business Trends .............................................................................................................................. 4

4 4 4 4

Injection Moulding Basics ...................................................................................................................... 5 2.1

Stages of Injection Moulding ......................................................................................................... 2.1.1 Plastication ......................................................................................................................... 2.1.2 Mould Filling ...................................................................................................................... 2.1.3 Packing and Solidification .................................................................................................

5 5 5 5

2.2

Differential Shrinkage and Cooling Effects ................................................................................... 5

2.3

Microstructure of Injection Mouldings .......................................................................................... 6

Material Selection .................................................................................................................................... 7 3.1

Material Bonding Properties ........................................................................................................... 7

3.2

General Material Properties ............................................................................................................ 7

Multi-Component Injection Moulding .................................................................................................. 9 4.1

Co-Injection Moulding ................................................................................................................... 9 4.1.1 Material Selection for Co-Injection Moulding ................................................................. 10 4.1.2 Co-Injection Moulding: Different Techniques ..................................................................11 4.1.3 Sequential Injection: Single Channel Technique ..............................................................11 4.1.4 Sequential Injection: Mono-Sandwich Technique ............................................................11 4.1.5 Simultaneous Injection: Two Channel Technique ............................................................ 12 4.1.6 Simultaneous Injection: Three Channel Technique ......................................................... 13 4.1.7 Part Design and Tooling Requirements for Co-Injection Moulding ................................ 15 4.1.8 Rheology and Mould Filling: Why and How Co-Injection Moulding Works ................. 15 4.1.9 Immiscible Materials Research in Co-Injection Moulding .............................................. 19 4.1.10 Co-Injection Moulding Applications - Case Studies........................................................ 20 4.1.11 Recycling and Legislation ................................................................................................ 21 4.1.12 Discussion and Conclusions ............................................................................................. 21

4.2

Bi-Injection Moulding .................................................................................................................. 21

4.3

Interval Injection Moulding .......................................................................................................... 22

Multi-Shot Moulding ............................................................................................................................. 22 5.1

Machine Technology ..................................................................................................................... 23

1

Multi-Material Injection Moulding

5.1.1 5.1.2 5.1.3

6.

7.

Injection Unit Configurations........................................................................................... 23 Plastication Design ........................................................................................................... 23 Machine Type ................................................................................................................... 23

5.2

Core Back Moulding ..................................................................................................................... 24

5.3

Rotating Tool Moulding ................................................................................................................ 25

5.4

Transfer Moulding ........................................................................................................................ 25

5.5

Multi-Shot with a Single Injection Unit ....................................................................................... 26

5.6

Material Selection for Multi-Shot ................................................................................................. 26 5.6.1 Material Properties ........................................................................................................... 26 5.6.2 Material Process Order ..................................................................................................... 27 5.6.3 Using Thermoset Materials .............................................................................................. 27 5.6.4 Liquid Silicone Rubber (LSR) ......................................................................................... 27 5.6.5 Thermoplastic Elastomers (TPEs) .................................................................................... 27

5.7

Multi-Shot Moulding Applications - Case Studies ....................................................................... 28 5.7.1 Trio Knob ......................................................................................................................... 28 5.7.2 Stanley Screwdriver ......................................................................................................... 29

5.8

Limitations to Multi-Shot Moulding ............................................................................................ 29

Over-Moulding ....................................................................................................................................... 30 6.1

Insert Moulding............................................................................................................................. 30

6.2

Lost Core Moulding ...................................................................................................................... 30

The Future? ............................................................................................................................................ 31

Additional References ................................................................................................................................... 31 Abbreviations and Acronyms ....................................................................................................................... 32 Abstracts from the Polymer Library Database .......................................................................................... 33 Subject Index ............................................................................................................................................... 105

The views and opinions expressed by authors in Rapra Review Reports do not necessarily reflect those of Rapra Technology Limited or the editor. The series is published on the basis that no responsibility or liability of any nature shall attach to Rapra Technology Limited arising out of or in connection with any utilisation in any form of any material contained therein.

2

Multi-Material Injection Moulding

1 Introduction Injection moulding is the most commercially important of all plastic processing methods. It allows production of intricate, high precision, three-dimensional parts at high production rates. Designers have long made use of the great variety of polymer materials commercially available for this process. This has enabled plastics to replace traditional materials such as wood, glass or metal in numerous applications.

have been split into three categories here: multicomponent, multi-shot and over-moulding. A brief description of each of these technologies and some of the names commonly used for them in the literature now follows. Each category is dealt with in detail in later sections of this review (Sections 4-6).

1.1 Multi-Component Moulding 1.1.1 Co-Injection Moulding

Whilst injection moulding can be considered a relatively young manufacturing technology, many variants of the basic process have been developed. Examples include processes such as injectioncompression, gas assisted, water injection, co-injection and over-moulding. Whilst processes such as gas assisted injection moulding can correctly be considered as multi-material processes, this report concentrates only on processes involving two or more polymeric materials. A number of processes fall into this moulding category, each suitable for specific market applications. An overview of the technologies covered in this review is shown in Figure 1. Various terminologies are used in multi-material moulding to describe particular process routes. These

Also known as dual injection, sandwich moulding, 2K (or 3K). This involves making sequential injections into the same mould with one material as the core and another as the skin. It can be recognised by the production of a defined skin and core structure. The core is fully encapsulated, to produce a sandwich like moulding.

1.1.2 Bi-Injection Moulding This is simultaneous injection of different materials through different gates as opposed to through the same gate as in co-injection moulding.

Figure 1 Process options for multi-material moulding

3

Multi-Material Injection Moulding

1.1.3 Interval Injection Moulding Also known as marbling. This is simultaneous injection of different materials through the same gate, with limited mixing. This produces a pattern of either regular or irregular colour distribution such as marble type effects.

1.2 Multi-Shot Moulding Multi-shot can be used to describe any process whereby distinct multiple material shots are applied to produce a single final component.

1.2.1 Transfer This includes processes, whereby preforms are moulded and then transferred to different cavities on the same machine in a process similar to over-moulding.

1.2.2 Core Back In core back moulding moving slides or inserts allow different parts of the tool to be opened to specific material feeds.

1.2.3 Rotating Tool In this method the tool is rotated between shots.

1.3 Over-Moulding This technique is where components are placed in an injection mould and are then moulded over with another material. The term over-moulding covers both insert moulding and lost core moulding, the latter produces a hollow component. This technique is not confined to plastics and over-moulding of metal inserts, such as to produce scissor handles, and on ceramics is commonplace.

1.4 Business Trends Multi-material injection is one of the fastest growing sectors of the injection moulding industry and all major machine manufacturers such as Arburg,

4

Battenfeld (119, 376), Demag, Engel (200) and Ferromatik Milacron (134), offer multi-material machine capability. The trend towards multi-material moulding has been pushed by the growing importance of added value manufacture (208), to give moulders commercial advantages over their rivals. An increase in the importance of material recycling has also aided the growth in co-injection technologies, where encapsulation enables recyclate materials to be used. A further factor pushing the popularity of multi-material moulding in Europe has been the transfer of much of the region’s traditional trade moulding market to the cheaper manufacturing sectors of the Far East. To combat the increased competition, trade moulders have sought more technically challenging markets as a means of survival, as much of the traditional standard injection moulding market has been, and continues to be, contracted out. The more technically advanced processes however, can often be done more efficiently and with higher quality by established multi-material tool makers and moulding shops in Europe. Whilst German manufacturers have been quick to invest in multi-material moulding technologies, moulders in the UK, the rest of Europe and the USA have taken longer to realise the potential advantages in these technologies. However, the versatility these processes offer to manufacturers, and the current highly competitive moulding market are now finally overcoming the resistance generated by the larger capital equipment investment often required to produce these mouldings. This is a positive step forward since a well designed multi-material component can often repay the initial investment quickly and easily. This is achieved by combining separate moulding jobs, such as when producing mouldings that then require assembly. By removing the need for the assembly step or perhaps a further finishing stage, a single multimaterial moulding can offer a considerable unit cost reduction. Of equal importance is that a more attractive end-product is often the result. Consider for example the case of the humble toothbrush. Application of multimaterial moulding to this product has transformed this simple and standardised design. The placement of combinations of hard and soft feel materials and a myriad of multiple colour combinations have filled endless supermarket shelves, with a variety of attractive designs for the consumer and in the process transformed the toothbrush market place. Each of the technology areas that have been introduced will be discussed in more depth in later sections.

Multi-Material Injection Moulding

However, first a quick reminder of injection moulding basics is presented which apply to all of the thermoplastic moulding techniques.

A low speed may cause an increase in injection pressure requirements due to a thicker frozen layer. This is because the molten material cools at the lower speed, meaning higher pressures are required to force other material in behind it. This can produce incomplete filling of the mould often referred to as short shots.

2 Injection Moulding Basics 2.1 Stages of Injection Moulding The injection moulding process can be broken down into four stages: • • • •

Plastication Mould filling Packing Solidification.

2.1.1 Plastication Plastication is the action of mixing and melting the feedstock. The polymer flow rate is governed by the material process conditions of the plastication stage and is a combination of material rheology, barrel temperature, shear, back pressure and screw speed. The basic aim is to produce a homogeneous and formable melt for the next stage where the material enters the mould. Compared to materials such as metals, polymers have very low values for thermal diffusivity of about 10-7m2/s. To overcome this, processing methods have developed which rely on plasticating relatively thin layers of polymer such as seen in the use of injection moulding screws. In this way, long residence times and low flow rates can be avoided. Once the polymer is plasticated then it is the flow properties that become of primary importance to the success of a processing operation.

2.1.2 Mould Filling The parameters of mould filling are of great importance to the quality of the finished article especially when considering factors such as warpage (orientation effects) and surface finish (skin formation). Filling dynamics are also thought to be the major factor affecting the levels of residual stress. It is important that injection speeds are reproducible as slight changes can cause variations in the product. Injection speeds that are too high can cause jetting (where the melt shoots through the gate and fails to adhere to the tool) and degradation and thus affect mechanical properties.

2.1.3 Packing and Solidification The packing stage’s purpose is to add extra material to compensate for the shrinkage caused by the increasing density of the solidifying polymer. If the additional polymer were not injected the component would shrink and warp due to non uniform cooling. Ideally the packing and cooling stages should be such that the final dimension is maintained as close as possible to design tolerances. Variables during this stage are packing pressure, packing time and the mould temperature. Bad mould design can lead to inconsistent cooling along the dimensions of the mould surface. This can cause increased residual stresses which lower the mechanical properties of the part as well as causing warpage.

2.2 Differential Shrinkage and Cooling Effects An easy way to examine the effects of differential shrinkage is to consider moulding on a centre-fed flat plaque. It is often found that radial shrinkage will be double that in the circumferential direction, this is due to orientation effects. Material will be orientated in the direction of flow and will shrink more in the direction of flow than perpendicular to it. It is not always possible to prevent this from occurring although the situation can be worsened by poor quality moulding techniques. This is because moulds fill in a so called ‘fountain flow’ pattern illustrated in Figure 2. The first material to enter the mould is under very little pressure as it flows into the channel, but as it proceeds towards the extremities of the mould, it is progressively cooled. The material that follows is hotter and begins to pressurise the material already there. As the mould has filled, a skin of solid plastic has formed on the wall. This causes a reduction in the effective gap through which later molten material must pass and so increases the shear rate. The extra shear stress causes orientation of the molecular structure and the melt is generally too viscous to allow for relaxation of all the stress that is developed. The result is that shrinkage of the material becomes much greater in the direction of

5

Multi-Material Injection Moulding

Figure 2 Schematic of fountain flow in mould filling

flow and orientation, i.e., in the radial direction, compared with that at right angles to it, i.e., the circumferential direction. Controlling the temperature of the mould can help to even out these effects. Of the moulding stages discussed, the parameters of mould filling, packing and cooling have been shown to be more important to final part quality than the initial plastication stage.

2.3 Microstructure of Injection Mouldings The effects on microstructure of the mould filling process can be seen in the injection mouldings of crystalline materials which typically exhibit a three layer microstructure due to the combined influence of flow, shear and temperature gradients. This is illustrated in Figure 3. Further details of studies on this topic are available (313).

Skin layer: This surface layer exhibits a high degree of frozen-in orientation as it freezes quickly against the mould wall. Intermediate layer: This is the shear zone present below the highly orientated skin layer. This region exhibits regions of different morphologies as a result of process history. Core: This has a coarse crystalline structure, the core remains molten for longer and is more insulated from cooling effects. The relative thickness of these microlayers depends on parameters such as mould temperature, injection speeds and tool geometry, as these in turn will affect cooling rates and crystal formation. Thinner sections will generally require faster injection speeds than thick walled parts, mainly because of the decrease in the importance of the relationship between mould filling time and cooling time with a thicker section.

Figure 3 Microstructure of a crystalline injection moulding

6

Multi-Material Injection Moulding

A common practice is to use a profiled injection speed that begins slowly and then increases. As the end of the filling stage approaches it is decreased again. A three stage profile is usually adequate in most cases. The switch from a high injection pressure and mould packing to a lower holding pressure is the most eventful in the moulding cycle as the material viscosity drastically increases. It is vividly described by Wagner (332) ‘as changing from flowing like honey to flowing like modelling clay’. This explains why consistently switching at the same point can make the difference between producing consistent parts by being in control of the process or producing rejects.

be affected by a significantly reduced section thickness. For example, imagine a 3 mm thick sandwich construction made up of two skin layers of 1 mm each and a core layer of 1 mm. If there is no adhesion between the skin and core then the depth of the surface material has effectively reduced from 3 mm with full adhesion, to 1 mm with no adhesion. Since the dimensions of the moulding affect many properties, the resultant properties may be those of only the 1 mm thickness skin material. For good adhesion, a certain amount of interdiffusion is required between the melts. This can be achieved when there is a high compatibility, or solubility.

Variations on this basic injection moulding method have been developed and include the multi-material methods under review here. Some material selection issues will now be presented.

Tables of compatible and incompatible material combinations are readily available from both machine (379) and materials suppliers, as illustrated in Table 1. However caution is required when using such tables, since it has been shown that changing from one particular grade of a material to another can affect the bond strength. Occasionally manufacturers may also seemingly disagree on the adhesion properties of materials. Since processing conditions also affect adhesion, experimentation may be required to ascertain optimum conditions for any given material combination.

3 Material Selection In selecting material combinations for multi-material moulding applications, consideration must be given to the combination of properties required in the final product.

3.1 Material Bonding Properties In many cases, there must be a certain level of adhesion between skin and core in order to maintain mechanical integrity (64). This can be achieved in two ways: 1) Compatible materials offer some degree of bonding at the interface 2) A method is found to mechanically interlock them. In the case of over-moulding and multi-shot this can be done with clever usage of material properties and tool design.

Compatibiliser additives are available and can be used to chemically bond some non-adherent materials. These substances usually contain a third polymer that bonds to, or is soluble in, the two materials. Numerous compatibilisers are commercially available to bond various immiscible materials together. Take for example PA6 and PP. These materials can be bonded by the addition of a maleic anhydride grafted polypropylene. However, compatibilisers tend to be expensive and both the number of chemical sites available at the interface (a result of the number of grafts per chain) and the molten contact time are limiting factors in the final bond strength as there is generally little interfacial mixing.

3.2 General Material Properties Not all parts require adhesion. In fact in some cases the requirement may be the exact opposite. If joints are to be produced, it is necessary that the mouldings can move freely at the interface. Examples include over-moulding to produce what will be the moving arms and legs on dolls and other similar toys, or to produce ball and socket joint mouldings. In cases like these, materials must be selected for their immisciblity to ensure smooth regions of movement. Where adhesion is required, good interfacial bond strength is a pre-requisite, otherwise the properties will

As well as adhesion, there are other material characteristics that also need to be considered when moulding with materials of different generic families. Examples are the levels of relative shrinkage and thermal expansion values, these may need to be matched or careful consideration given to the requirements before final material selection takes place. Certainly in the case of many co-injection techniques, differences in mould shrinkage and thermal expansion can lead to problems such as sink

7

Multi-Material Injection Moulding

EVA

PBT

PC

PE-HD

PE-LD

PET

PMMA

POM

PP

PPOmod

PS-GP

PS-HI

SAN

TPU

+

+

+

+

+

-

-

+

+

-

-

-

*

*

+

+

ASA

+

+

+

+

+

-

-

+

+

-

-

-

*

-

+

+

EVA

+

+

+

+

+

+

+

+

PA66

ASA

ABS

PA6

ABS

Table 1 Material compatibility table

+

PA6

+

+

*

*

*

*

-

*

-

-

-

+

+

PA66

+

+

*

*

*

*

-

-

-

-

-

+

+

-

-

-

-

-

+

+

-

-

-

-

-

+

+

PBT

+

+

*

*

+

+

-

-

+

-

PC

+

+

*

*

+

+

-

-

+

PE-HD

-

-

+

*

*

-

-

+

+

-

*

*

-

-

-

-

-

-

PE-LD

-

-

+

*

*

-

-

+

+

-

*

*

+

-

*

-

-

-

PET

+

+

+

+

-

-

+

-

-

-

-

-

PMMA

+

+

-

*

*

-

+

*

-

-

-

+

POM

-

-

-

+

-

-

-

-

-

PP

-

-

*

-

+

-

-

-

-

-

PPO mod

-

-

PS-GP

*

*

PS-HI

*

SAN TPU

+

-

-

-

-

*

*

*

-

-

-

-

+

-

-

-

-

-

-

-

-

-

-

+

+

+

*

-

+

-

-

-

-

-

*

-

-

-

-

+

+

+

-

-

-

+

-

-

-

-

-

-

-

-

-

-

+

+

+

-

-

+

+

+

+

+

+

+

-

-

+

-

-

*

-

-

+

+

+

+

+

+

+

+

-

-

-

-

-

-

+

+

+

+

- No adhesion, * Poor adhesion, + Good adhesion

marks, warpage and residual stresses. With overmoulding techniques, differences in shrinkage or the coefficient of linear thermal expansion (CLTE) can produce high stresses between restrained materials. The result in both cases can be the same, premature failure.

•

Time-temperature effects: Many properties are temperature dependent: stiffness, ductility and impact strength may vary considerably with temperature. Therefore, testing should be carried out at conditions representative of the service conditions.

Consideration should also be given to the long-term properties of the various plastic materials making up a multi-material component, especially if the moulding is to be put under stress. Stress can be produced during the processing stage, especially if unsuitable processing conditions are used. In service, factors such as mechanical stress, chemical attack or high temperature may be found. All relevant design parameters should be considered as well as those of shrinkage and CLTE previously mentioned. Dependent on the application these may include:

•

Fatigue: Dynamic fatigue can occur when stress is applied periodically in applications such as bearings.

•

Creep: Where parts are exposed to constant loading there may be a change of stiffness with time (creep).

•

Environmental stress cracking: Plastics may be embrittled by exposure to water, light, temperature and oxygen as well as chemical attack.

8

Multi-Material Injection Moulding

This section has given an overview of material selection that can be applied not only to multi-material mouldings but also in many cases to standard plastic components. If all relevant process and design criteria are considered at an early stage, conversion to multi-material processes should be a relatively painless transition. Further material considerations for individual processing techniques along with current applications and markets can be found under the relevant technology section.

4 Multi-Component Injection Moulding This method describes a process whereby plastics are injected into one mould during a single injection cycle. The most common process in this category is coinjection moulding. Other less common variants are bi-injection and interval techniques.

4.1 Co-Injection Moulding Co-injection moulding (105, 168, 270) is a variant of the standard injection process and has been in use since the early 1970s. The co-injection process was first described

and developed by ICI in 1970 and was developed to overcome the surface finish limitations inherent in the structural foam process. Foam mouldings have a rough, irregular surface finish which will vary in quality from moulding to moulding. By using a solid skin with a cellular foamed core, it is possible to obtain a surface finish as good as for a solid part but with the added rigidity of the foam core. There is also the reduction in material cost associated with foaming. This requires fewer raw materials and is therefore cheaper to produce. In products with thickness above 4 mm, for example some automotive body panels, this method is often used. A number of terminologies are used that can encompass this process such as sandwich moulding, 2K (2component) or 3K (3-component) and dual-injection or multi-component. For the purpose of this review, coinjection moulding is the preferred terminology. This technique offers the advantages of combining two or more material properties to produce a ‘sandwich’ structure. This is achieved by making sequential injections into the same mould. In co-injection moulding two compatible melts are injected either sequentially or simultaneously into the mould thus forming a layered structure. The melt injected first forms the skin, whilst the melt injected afterwards forms the core. This is illustrated in Figure 4. The result is the distinctive sandwich structure of skin and core as shown in Figure 5.

Figure 4 Encapsulation of core material by skin during co-injection moulding

9

Multi-Material Injection Moulding

Table 2 Current applications for co-injection mouldings Material combination

Properties

Application

Soft feel skin/hard core

High strength core with soft feel skin

Door handles, gear lever (a.1)

Unfilled skin/core with conductive filler

Electromagnetic interference shielding (EMI) (380)

Computer housings

Virgin skin/recycled core (378)

Environmentally friendly production, cost saving

Garden furniture, automotive bumpers and fascias (70)

Unfilled skin/reinforced core

High surface finish, structural performance

Automotive door handles (163)

In mould paint/variable core

No finishing of product required after moulding

Wheel trims (a.2)

Unfilled skin/foamed core

Good surface finish, low density, high rigidity

Automotive body panels (315)

Pigmented skin/uncoloured core (or reverse)

Reduced pigment cost, aesthetics

Yoghurt pot

Figure 5 Cross section of sandwich structure of a co-injection moulding

Using two polymers with different properties makes it possible to obtain unique property combinations that are not possible in ordinary injection moulding. A number of these including commercial applications are shown in Table 2.

4.1.1 Material Selection for Co-Injection Moulding One of the most difficult technical problems with coinjection moulding is that the core material must be prevented from large scale mixing with the skin material, in order to retain a consistent skin layer thickness and resultant properties. It must also be prevented from penetrating the skin of the moulding. There are also limitations in the variation of flow characteristics between the two materials that are

10

permissible. Rheology plays a large part in the relative skin/core distribution. Therefore the viscosity of the materials is of the utmost importance as this affects the process dynamics and resultant core distribution. As a general guide, in order to keep the sandwich configuration and layer thickness consistent, the skin should have the same or preferably a slightly lower viscosity than the core. If the skin viscosity is too high, the core melt will flow through the skin and form the surface layer. Core distribution can also be controlled by adjustments to the speed and time of injection, polymer melt temperatures and mould temperature. However, the use of similar moulding temperatures for both materials is recommended, since they are processed simultaneously. The rheology of the materials will be discussed in more detail in Section 4.1.8. The process does have limitations. There is a need for the skin and core materials to be compatible with each other in terms of adhesion and shrinkage. Adhesion of the layers is necessary to prevent the core material becoming detached from the skin especially if the moulding is likely to be exposed to mechanical loads. Therefore materials must be compatible or a suitable compatibiliser used in the core component. The use of compatibilisers in the core component of co-injection moulding was developed and patented by the Rover Group in collaboration with University of Warwick (246). Researchers from Warwick have also developed and reported methods to mechanically interlock immiscible materials for co-injection moulding but these are currently in the early development stages (25).

Multi-Material Injection Moulding

4.1.2 Co-Injection Moulding: Different Techniques There are a number of variations of the co-injection moulding process which have been developed. They can be split into two types, sequential injection and simultaneous injection. These methods will now be introduced and the advantages and disadvantages of both discussed.

of polymer flows can cause the flow to stop, giving surface defects such as shadow marks or gloss marks on the mouldings. In terms of skin/core structure, as with all co-injection mouldings changing injection moulding parameters or the relative material viscosity can be used to control material. This process is mainly used for thick sectional parts with foamed cores.

4.1.4 Sequential Injection: Mono-Sandwich Technique

4.1.3 Sequential Injection: Single Channel Technique The single channel method was patented by ICI in 1970 and was the first commercial co-injection technique. An injection moulding machine with two cylinders is used, one for the skin material and one for the core. The polymer melts are injected sequentially into a mould, first the skin and then the core. A specifically designed valve is used, which allows a first injection of skin material only. At a preset point, the flow is stopped and the core is injected. At the switch point from one extruder to another there is a pressure drop in the mould. This is the major limitation of this method. This switching

The mono-sandwich technique (220) was developed by Ferromatik Milacron. It uses two materials layered in a standard cylinder and is shown in Figure 6. This is achieved by melting the skin material in a separate side extruder that plasticates the material. A special hot runner system then leads the molten material through to the front of the screw in the main cylinder. The resultant melt pressure pushes the screw backwards. When the specified amount of melted material has accumulated in front of the screw, the screw starts rotating and feeds the core material. The injection is then carried out in the same way as for normal injection moulding by pushing the screw forward.

Figure 6 Ferromatik mono-sandwich technique

11

Multi-Material Injection Moulding

There is little or no mixing of skin and core melts in the screw as the dynamics of the screw push the material forward rather than mixing the melts together at the material interface. The maximum amount of core material that can be encapsulated will be entirely dependent upon the mould geometry. For simple symmetrical parts this value will be around 65-75% by volume. The main advantage with this method is that a standard injection moulding machine can be rebuilt to a sandwich machine simply by connecting a side extruder to the main injection unit. This method is also particularly good where very thin-walled parts are required. A further advantage reported by the manufacturer is the speed of colour and material change compared to other sandwich techniques due to the relatively simple construction. Since injection is made in the same way as for normal injection moulding the process control is fairly simple and similar to that of standard injection techniques. The drawback to this method is that by feeding through one injection unit only, there is a lack of detailed control which is required when moulding complex shapes to control skin/core configuration. A modified version of the mono-sandwich injection technique, was originated by Addmix (219). It is a similar technique to the Ferromatik one but without an ancillary extruder. The second material feedstock is regulated and fed to the screw from a separate hopper controlled by a stroke measurement system, with injection through a special nozzle. In this way the polymers are layered into one injection cylinder. The moulding then proceeds as per conventional techniques. In summary, sequential injection techniques provide a cheap and useful method for producing sandwich mouldings. It is a technique more suited to simple geometries since the main problem with sequential injection is the lack of control in the skin/core distribution. With the melt stream injection of both skin and core controlled together and with just one velocity profile, skin thickness cannot be adjusted in various parts of the moulding. To overcome these problems, the simultaneous injection method was developed. Here skin and core velocities can be controlled separately giving enhanced control.

4.1.5 Simultaneous Injection: Two Channel Technique The two channel method, developed by Battenfeld in the mid-1970s, includes a phase of simultaneous injection. The process sequence can vary but a typical example would be:

12

1. Injection of skin to a preset switch point 2. Injection of core material begins so both skin and core flow together 3. Injection of just core 4. Injection of just skin 5. Part packing and cooling followed by ejection. This co-injection moulding process entails the injection of molten plastic for the skin layer into the mould cavity. After a certain preset time, usually in the region of 0.1-0.3 seconds, a second plastic that will make up the core is injected and for a period there is simultaneous injection of both materials. This simultaneous period of flow is where this process gets its name and also how it differs from the sequential techniques described earlier. The injection of core material pushes the moving layer of skin material against the cavity walls where it cools and solidifies. The final stage of mould filling is injection of the core material only, although sometimes the mouldings are ‘capped’ with skin layer to complete encapsulation of the core. Two injection units are used in this method, which are joined through a specially designed nozzle. In the Battenfeld design, the nozzle is equipped with two separate concentric channels that can be independently operated, opened and closed hydraulically. This allows the process sequence to be carefully controlled. A phase of simultaneous injection of skin and core avoids the problems inherent in the single channel technique by maintaining a constant flow front velocity. This can be seen by looking at Figure 7 and comparing the pressure profiles and screw velocity of the simultaneous and single channel methods. In the sequential method, the period of stagnation after injection of skin (A) but before injection of core (B) can be clearly seen, resulting in a drop of cavity pressure and a period where there is no movement of material in the screw. This demonstrates many of the limitations of sequential injection discussed earlier. This pressure drop is less apparent in the simultaneous method. The length of the simultaneous injection phase depends on both the material and the mould geometry. A typical duration is 25% of the injection time for the skin component. Mould filling dynamics dictate that optimum distribution of core material is

Multi-Material Injection Moulding

Figure 7 Comparison of mould filling of simultaneous (left) and sequential (right) injection moulding

obtained if the skin viscosity is kept slightly lower than that of the core. This is due to rheological factors that will be explained in the next section. Separate operation of two injection units makes it easier to control skin thickness in various parts of a moulding. This is because by separate control of the velocity profile of the skin and core, the skin thickness can be adjusted in various parts of the moulding. Extra amounts of skin material can also be injected during holding time to seal the gate area, which also ensures that the nozzle is clear of core material and prepared for the next shot. Due to the dynamics of mould filling, material entering the tool and cooling on the walls near the gate can get remelted and flushed away due to frictional heat generated by the incoming molten flowing melt. This can lead to variations of skin thickness and leave the skin near to the gate region much thinner than that on the rest of the moulding. This effect is generally more pronounced on the opposite side of the gate due to the higher shear experienced in this region. In order to overcome this the three channel technique was proposed.

4.1.6 Simultaneous Injection: Three Channel Technique With the three channel technique, an extra channel is used for the skin in the centre of the gate in order to retain skin thickness in this area. An example of a system developed commercially by Kortec is shown in Figure 8. This is an example of a hot manifold system. Systems are also marketed by other companies including Kona, Incoe and Battenfeld (70). The extra channel can reach the opposite side of the moulding, enabling the two surfaces to be regulated separately and surface thickness controlled. This special design can only be used with a central gate, otherwise skin/core distribution will be irregular as detailed in Figure 9. For other gate geometries or multi-cavity mouldings, the two channel or single channel technique is preferred. A three layer technique to combine immiscible material combinations was provided by the Billion Corporation of France (375). Their solution to polymer incompatibility for sandwich injection moulding used the third intermediate polymer layer as a binder adhesive, this is analogous to methods used in extrusion blow moulding. However, there are obvious machine-

13

Multi-Material Injection Moulding

Weld lines are skin rich due to filling dynamics Effect of gate position on the distribution of core material using various mould geometries

Figure 8 Kortec three-channel nozzle technique

Figure 9 Gate position effects on core material distribution (a.3)

Figure 10 Battenfeld three channel technique

14

Multi-Material Injection Moulding

cost disadvantages here, because the runner system is complex and a third injection unit is required. The Battenfeld solution to three-channel moulding is shown in Figure 10. This utilises machine configurations also used in multi-shot techniques as will be described in later sections. The vertical unit can be used to feed the third material into a combined nozzle system based on their two-layer technology described in Section 4.1.5.

4.1.7 Part Design and Tooling Requirements for Co-Injection Moulding Normal injection moulding tooling can be used for both sequential and simultaneous co-injection moulding providing the following factors are considered. Mould filling and the resultant skin/core distribution is strongly dictated by the gate location as shown in Figure 9. The injection gate must be designed with consideration for the resultant skin/core distribution otherwise unsatisfactory mouldings may result. If more than one gate is required, or a break in the flow front is produced, the weldline will be skin rich, as the core materials will not completely meet due to the filling dynamics of co-injection moulding. The skin will always pack these areas before the core material can reach them.

4.1.8 Rheology and Mould Filling: Why and How Co-Injection Moulding Works For readers who have not seen co-injection moulding in action, it can be very difficult to understand how coinjection moulding can produce the distinctive skin/core

structure. It should be remembered that the skin material is injected first to cool and form the skin against the tool wall. The core material will then push against the skin to cause it to penetrate deeper into the mould cavity. In this process therefore the core remains encapsulated, providing that the viscosities of the skin and core are similar. If they are mismatched, this filling pattern is affected. Before this is discussed further, a recap on rheology basics and the effects of various parameters on viscosity is required. How a material responds to changes in temperature, shear and pressure can greatly affect processing methods and strategies. Other material properties such as density, elasticity, thermal expansion and thermal conductivity can also affect processing behaviour through, for example, decisions on the cooling rates required, shrinkage tolerances and die swell. However, discussions will begin with the basics of rheology.

4.1.8.1 Rheology Basics Rheology deals with deformation and flow and examines the relationship between stress, strain and viscosity. Most rheological measurements measure quantities related to simple shear such as shear viscosity and normal stress differences. Material melt flows can be split into three categories, each behaving differently under the influence of shear as shown in Figure 11, i.e., dilatent (shear thickening), Newtonian and NonNewtonian pseudoplastic (shear thinning). In an ideal Newtonian liquid flow, the viscosity is independent of shear rate. Plastics fall into the category exhibiting shear thinning behaviour. This means they respond to increased shear by a drop in viscosity. It can be seen from Figure 11, however, that all melts

Figure 11 Typical stress/shear relationships (left) and apparent viscosity/shear curves (right)

15

Multi-Material Injection Moulding

approximate to Newtonian fluids at very low shear rates. Unfortunately injection moulding tends to occur at high shear rates. Temperature and pressure also affect the viscosity of the polymer melt. At higher temperatures the viscosity drops, whilst as pressure increases viscosity increases. A complex picture now emerges, as during injection moulding there are both steep gradients of temperature and pressure. Therefore during co-injection moulding materials will be subject to viscosity change throughout the moulding cycle with the skin and core undergoing different shear, temperature and pressure histories. A further consideration is the response of the skin and core polymer flows, during injection moulding, to the deformation processes present. This is a complex mixture of shear, elongation and bulk deformations. One way to try to model such effects is to use an element model. A representation of a theoretical polymer element is shown in Figure 12. This indicates how stresses can occur in a number of directions. Representations such as these are often used to show the force balance on an element. There are three components of normal stress (xx, yy and zz in Figure 12) and six components of shear stress, giving a total of nine stresses (on the three visible planes) using this method of analysis. Shear flow is produced when stress is applied tangentially. Extensional flow is the result of stress applied normal to the surface of the material and bulk deformations result when stress is applied normal to all faces. During shear flow, polymer chains are deformed and orientate in the direction of flow. (The results of this

orientation in standard injection mouldings was discussed in Section 2.2). The tension of the polymer in the flow direction is called the first normal stress. In contrast to this, flow in other directions is relatively small. First normal stress can be defined by the difference between the normal stress component in the flow direction and the normal component in the direction of the shear plane. Combinations of some or all of these forces are applied to the molten polymer material during the moulding process dependent upon where on the moulding they are. Analysis using methods such as these, allows material interactions to be better understood.

4.1.8.2 Impact of Rheology on the Dual Injection Process Now some of the factors affecting viscosity have been introduced, the effect of viscosity on skin/core formation can be studied. This is illustrated in Figure 13. High viscosity melts flowing into low viscosity melts will force the low viscosity material in front of it. Low viscosity melts flowing into high viscosity melts will jet through areas of least resistance, giving an effect termed ‘melt fingering’. This type of effect can also be seen in gas assisted injection moulding where the core component, gas, has an effective viscosity of zero. The injected gas follows the path of least resistance, making channels in the hottest, thickest and least viscous parts of the melt stream. Breakthrough of the core component in co-injection moulding can cause unwanted surface defects, whereby the core material can be visible in the corners of the mouldings. Therefore, a high percentage

Figure 12 Possible stresses on an element

16

Multi-Material Injection Moulding

Figure 13 Interface behaviour of melts of different viscosity

of co-injection studies have investigated the relationship between the relative viscosities of the materials used within the process and the resultant skin/core distribution to reinforce these findings.

4.1.8.3 Previous Studies on the Effects of Viscosity Ratios It was reported as far back as 1974 that two-phase flows as found in co-injection moulding are sensitive to differences in the rheological properties of the melts. Different rheological combinations produced different skin/core ratios. Later the simultaneous system driven by viscosity encapsulation phenomena was proposed as illustrated in Figure 13. Somnuk and Smith (319) produced one of the first viscosity ratio guides for polypropylene skin and core systems. Their method was to test a number of viscosity ratios within a number of different mould designs to discover how much material could be included in the core of a moulding and what ratios provide optimal results. It was found that the most uniform core distributions were achieved at viscosity ratios of skin to core between 0.8 and 1.8. Within these ratios about 60% core could be concealed within a square flat plaque moulding without breakthrough, and about 70% core in a disk mould. Other researchers have since published similar findings. Apart from initial viscosity, the moulding parameters found to have most effect on the skin/core distribution are the melt temperature, the injection

rate and the length of the simultaneous phase. Too short an interval between the injection of skin and core can result in breakthrough, too long and too much skin is forced to the outer edges of the moulding. In terms of other processing effects it has also been found that as in injection moulding, there is considerable melt flow in the region of the gate during the post-filling process of co-injection moulding. This can have implications for the skin thickness around the region of the gate. From injection moulding it is well known that both the temperature of the mould and the speed at which the materials are injected into the mould cavity also determine the end structure. The temperature of the mould will affect the rate at which the skin material will freeze, the greater the difference in temperatures of the skin and the mould surface the more quickly the material will solidify. The rate at which the skin material is injected will determine how much time the leading edge of the skin material will have in contact with the mould surface. A greater speed would lead to the skin material penetrating further into the mould. In relation to these parameter effects in coinjection moulding, increasing injection speeds of skin material can help prevent breakthrough. Slowing down the core gives a similar, though not exactly the same, effect. This is because as skin speeds are increased, especially at low mould temperatures, instabilities in the flow can also increase. These instabilities can result in a better mixing in the interfacial region between skin and core material. However, taken to extremes these instabilities could also cause breakthrough in the mouldings.

17

Multi-Material Injection Moulding

Since viscosity is shear dependent it is worth considering what kind of shears are operating within a mould tool. This is in order to ensure that the viscosity data being used is representative, or at least a close approximation, of what is actually occurring. An example of such data is shown in Figure 14. It can be seen how the viscosity changes in relation to both shear and temperature. The method used to measure these materials is called capillary rheometry and unlike other methods used to quantify melt flow properties such as melt flow index (MFI) and cone and plate rheometry, this method can actually measure the response of a material at the high shears associated with injection moulding.

This becomes of even more importance when different generic polymer families are being used as skin and core. A diagram of the viscosities of polycarbonate (PC) and acrylic (PMMA) is shown in Figure 15. This combination of materials is of interest for future automotive glazing applications (112). It can be seen that not only does viscosity change with shear, different material families also respond differently to changes in shear. A second consideration is temperature, as viscosity is also a function of temperature, so this data must also be representative of the moulding conditions, in this case mouldings were produced with a 20 °C difference in skin and core. The data reflects this. In Figure 15 at shears below 1000 s-1,

Figure 14 Effect of temperature on viscosity of polypropylene

Figure 15 Viscosity versus shear for PMMA and PC

18

Multi-Material Injection Moulding

the polycarbonate (PC) material has the lowest viscosity. At shears higher than this the trend is reversed. Therefore if mouldings were carried out on identical injection moulding cavities but one tool had a higher shear at the gateing region, the viscosity interaction would be different. Examples such as these highlight some of the possible pitfalls inherent in co-injection moulding. In checking for viscosity matching it is therefore essential that the data used is relevant to the processing temperatures and shear rates within the tooling. Whilst viscosity ratios between the core and skin materials have a major impact on the interface of the materials and the core distribution. It is not the only factor. With mixed material studies complex mechanisms have been found to occur at the interface. A rheological explanation for such effects is insufficient on its own to explain the interfacial effects that are observed, with increases in injection speed appearing key to these studies. Polymers have both viscous and elastic components. Given the high shear rates employed during injection moulding and the relationship between increases of elasticity with shear, it seems reasonable to assume that elastic effects will occur. An increase in injection speed would bring about an increase in shear and therefore also increased elastic property effects in the mouldings. Therefore the resultant mechanical properties, for example, impact strength or tensile modulus, may vary as a result of both viscous and elastic interfacial interactions.

4.1.9 Immiscible Materials Research in Co-Injection Moulding If two immiscible materials are moulded using coinjection moulding, it is possible to peel them apart because there is both no adhesion and no mixing of the two materials. (Obviously the properties of such mouldings will be poor where there is no adhesion.) This is because filling occurs by fountain flow in an organised laminar manner giving little mixing between the material being injected and the molten material coming in behind it. Fountain flow was illustrated in Figure 2 and it is as a result of this mechanism that the core structure will tend to have a concave edge configuration. If laminar flow is disrupted, the normal mould filling pattern is disrupted. Small scale interfacial interactions occur driven by a complex mixture of elastic and viscous interactions which disrupt the stratification at the interface. A common example of fountain flow failure occurs in standard injection moulding. This is the phenomenon of ‘jetting’ whereby the melt shoots through the gate and therefore fails to gain adhesion to the tool cavity. The result is commonly seen as snake like markings on the final moulding. In co-injection moulding, jetting of this type can disrupt the filling pattern and make it difficult and sometimes impossible to obtain skin core configurations, an example of this is shown in Figure 16.

(a)

(b)

(c)

(d)

Figure 16 Co-injection mouldings produced with non-laminar flow (a, b), with laminar flow (c) and melt fingering (d)

19

Multi-Material Injection Moulding

The moulding parameter of major importance in the control of jetting is injection speed with lower speeds resulting in less jetting behaviour. The viscosity will also affect jetting behaviour. However, with adequate tool gating design this should not be an issue unless very high injection rates are used. It does, however, provide a useful insight into the filling mechanisms at work. There is not a great deal of literature in the public domain relating to the co-injection moulding of two immiscible polymers. Both Selden (177) and researchers at the University of Warwick have studied the adhesion characteristics of the nylon/polypropylene system with a maleic anhydride compatibiliser. Selden reports the appearance of viscous fingering in his mouldings, which seemed to increase with increasing compatibiliser levels. This effect is seen in Figure 16(d). It is similar to the viscous fingering commonly seen in gas assisted injection moulding. Selden attributes this effect to polymer instabilities. Analysis of cross-sections of mouldings from research identified microlayers of skin/core mixing. Selden noted a stronger effect away from the gate area and that near the gate the effect disappeared. In terms of the interface, the main factor in adhesion strength was the thickness of the skin layer. This being due to the increased bonding time available for adhesion with a thicker and therefore slower cooling interface. A thinner layer would also be subject to higher shear from incoming molten material and be more likely to be remelted and swept away into the melt stream. This would tie up with the earlier claim of Selden that the microlayers disappeared towards the gate area as this would be the area most subject to remelting from shear effects from incoming material. Instabilities in co-injection mouldings can be split into two types: •

Voscous effects: viscosity interactions, for example melt fingering, caused by viscosity differences in the melt streams, and

•

Elastic effects: interfacial instabilities caused by localised interfacial mixing at the skin/core boundary producing microlayer structures.

The extent of the microlayer formation will depend on both the viscosity encapsulation mechanism and the stress differences induced at the skin/core interface. These stresses are a result of the process history and parameters, for example, injection speed differences between skin and core components.

20

Therefore, to keep skin thickness consistent across a co-injection moulding, viscosity and moulding parameter effects need to be controlled. It has been found that injection speed is the key parameter in getting uniform skin distribution. Lower speeds being most effective. This will also minimise disturbances in laminar fountain flow especially in the gate region at higher speeds in co-injection moulding. Using materials of different generic families, be they immiscible or compatible, there is likely to be a different elastic response to shear and stresses within the mould at the skin/core interface, especially in high shear tooling. This instability will affect the mixing dynamics within the interfacial area and in some cases may cause surface defects on the skin/core interface as a result of stress differences. However, new developments are allowing immiscible parts to be combined through compatibilisation or through mechanical techniques, and it is likely that commercial interest in such material combinations will push further research. There are two obvious areas for growth, firstly the recycling potential in this technology for mixed materials combinations and secondly the possibility to combine distinct jobs in one in-mould operation. An example of this is to produce in-mould primers for polypropylene (314) to improve paintability or adhesion. This removes the need for the pretreatment stages currently used. Examples of current applications for co-injection techniques now follow.

4.1.10 Co-Injection Moulding Applications Case Studies 4.1.10.1 Preforms for Blow Moulding Injection blow moulding is commonly used to produce containers such as polyethylene terephthalate (PET) carbonated drinks bottles. In this method, preforms are injection moulded and then inflated in a separate operation. Core bars are used to transfer mouldings from the moulding station to the inflation station. Multilayer extrusion blow moulding has been practised for some time with nine or even more distinct layer configurations possible. Multi-layer with injection blow moulding is a newer development (145, 152, 274).

4.1.10.2 Thermoplastic Olefin Elastomer (TPO) Fascia and Bumper (70) Automotive applications require reduced cost and potential recyclability to meet European Union (EU) Endof-Life vehicle legislation requirements (see next section).

Multi-Material Injection Moulding

•

High capital cost. Co-injection machines are around 40% more expensive than an ordinary injection moulding machine.

•

Restrictions with regard to mould geometry: parts with sharp corners, changes in wall thickness, ribs or bosses are difficult with co-injection moulding due to the problems of distributing skin and core materials.

•

Packaging manufacturers must consider the Directive on Packaging and Packaging Waste, Directive 94/62/EC.

Restrictions with regard to material combinations. Even for compatible materials, the choice of a particular grade could influence adhesion and give inferior properties. Since processing conditions can affect the rates of inter-diffusion of skin and core, they can also affect the properties of the final component. Again, the effects are complicated and not well understood.

•

Automotive manufacturers and suppliers must comply with the End-of-Life vehicle directive (ELV), Directive 2000/53/EC.

Weld lines; at weld lines there is only skin material, and special solutions, like overflow channels, are necessary if the core material is needed here.

•

Rheology and process parameters play a crucial but poorly understood role in both mould filling and material distribution at the interface. This is due to the complex interrelationships that exist between the skin and core material viscosities and the changes in shear, temperature and pressure that occur during the moulding process.

Co-injection offers not just the potential to incorporate recyclate in the core but also to utilise post industrial painted recyclates. One such example is the Ford P207 Fascia which uses recyclates in this manner to achieve part recyclability. Once the initial capital machine cost is overcome it is also an economical approach in terms of both material utilisation and recycling potential.

4.1.11 Recycling and Legislation The TPO fascia is an example of the recycling potential inherent in the co-injection moulding technique. Environmental legislation affects a number of sectors of the plastics industry. This legislation varies globally, examples in the EU include: •

•

•

The electronic and electrical equipment manufacturers must comply with the future demands of the proposed directive on waste electrical and electronic equipment (WEEE), Directive 2000/0158 (COD).

Other similar legislation is in place in countries such as the USA and Canada. What this means in real terms is that many current and future plastic applications will demand a consideration of recycling capability. If just world wide injection mouldings alone are considered the quantities of material requiring recycling will be considerable. In this respect co-injection moulding is an ideal solution. Recyclate materials can be buried in the core, and with the exception of transparent materials and tooling of complex geometries or multiple gating (see Section 4.1.7), standard injection mouldings can easily be switched to co-injection moulding. With this in mind it is therefore highly likely that this method will become much more widely utilised in the future.

4.1.12 Discussion and Conclusions Co-injection moulding provides processing routes for obtaining property combinations that are, in general, not possible with conventional injection moulding. However, there are a number of factors that have tended to limit the commercial uptake of co-injection moulding technologies.

However, with the increased need to meet environmental recycling legislation and targets, in addition to an increased understanding of the process, it is likely that the uptake of co-injection technology will continue to rise in future years.

4.2 Bi-Injection Moulding In bi-injection materials are injected simultaneously at different points into a tool. In this manner it has features of co-injection (simultaneous injection of two materials but through one nozzle) and core back moulding (where injection is at two points but in sequence). Moulding in this manner gives a shorter cycle time than core back moulding. It is another method of achieving the usual requirements of multi-shot such as multi-colour or hard/soft combinations. The knit-line is stronger due to the higher temperature at the interface when the flows meet. However, the materials do not maintain good separation and definition at the interface, which can be a problem in potential applications for this technique.

21

Multi-Material Injection Moulding

4.3 Interval Injection Moulding This method produces marbling type effects and is generally, though not always, confined to mouldings of different coloured materials of the same type. This can produce a random or regular colour distribution pattern as required. Materials are injected in either a simultaneous or sequential manner from a combined nozzle. This is similar to methods used to produce coinjection mouldings. In this case however, injection is not used to produce a skin/core configuration, the material flows together and small-scale mixing operations take place but not at a level to completely mix the two materials together. In the method marketed by Arburg, ‘the two injection units are coupled together using a special interval unit, inside which the mixing nozzle is located’ (a.4). The resulting colouration is controlled by the mixing dynamics of the materials in question and the shear they are subject to, for example, by the size and position of the sprue. Injection can be simultaneous or set on an alternating cycle to give a pulse type effect. The size of the injection steps and the speed of injection will also alter the colouration of the resultant moulding. Applications tend to be for mainly cosmetic applications such as covers and boxes and applications such as buttons where the colouration can be used to decorative effect.

5 Multi-Shot Moulding Multi-shot moulding has been around for over thirty years and is used as a method of placing materials either side by side (abutting), one on top of the other

with an overlap, or superimposition of one shot onto another. To do this special tooling and machinery is required. Common examples of such mouldings are keypads with the numbers made of one colour and the letters moulded-in using another colour, the advantage of this technique being the elimination of the printing processes which would otherwise be required to mark the keypads. Multi-colour automotive tail-lights are also made by this technology. Another common application is to combine hard and soft materials to produce a ‘soft feel’ component. Handles such as on doors or toothbrushes are common products benefiting from this technology. Multi-shot moulding techniques are well established, their growth being pushed by the development of thermoplastics elastomer (TPE) materials, enabling rigid and flexible material combinations to be employed. These can also be seen in a variety of applications from automotive seals to bras (79). A number of moulding methods can be employed to produce multi-shot mouldings but those produced from the same material in multi-colour multi-shot enjoy the highest market share. Multi-shot techniques produce not only multi-colour but also multi-material mouldings. The most common methods are the use of tool rotation, the core back technique and transfer tools. Transfer tools can be used to move shots from one cavity to another, this technique is very similar to over-moulding. These processes will be described in detail. Some applications for multi-shot moulding are listed in Table 3.

Table 3 Applications for multi-shot mouldings Material combination

Properties

Application

Same material/different colours

Aesthetics

Buttons, mobile phone casings (98), toothbrushes, automotive light casings (375)

Soft feel/hard feel (131)

Increased customer appeal through ‘soft touch’ properties

Various handles, toothbrushes (104), cameras (59), screwdrivers, kettle handles (306), vacuum cleaners, lawn mowers and electric toothbrushes (104)

Transparent/coloured

Viewing panel incorporated into moulding

Light casings (375), battery casings (325)

Very flexible TPE, hard substrate

Sealing properties

Lids with moulded on seals

Liquid silicone rubber (LSR), hard substrate

Sealing properties

Seals

22

Multi-Material Injection Moulding

5.1 Machine Technology Multi-shot processes, as the name implies, require multiple shots of material to make a single component. For each one of these materials an injection unit is required. To mould these multiple shots also requires special tooling and equipment. Multi-shot capability can be built either into the injection tool or controlled by the injection moulding machine. To enable multi-shot, multiple injection units can be arranged to feed machines in a number of ways as the next section will explain.

5.1.1 Injection Unit Configurations Multiple injection units can be arranged around the clamping units as combinations of horizontal and vertical units in piggy backed or right angled configurations. These are shown in Figure 17. Using a vertical injection unit can save space and hence is the most used position for multi-shot moulding at the split-line. For mould changing, the units can be slid towards the nozzle. Where the vertical position cannot be used, perhaps because of lack of factory height, the second unit can be positioned at right angles. The position of the unit can be adjusted both horizontally and vertically, although the latter is available as an option rather than as standard, by some manufacturers. Again the vertical units can be moved to the nozzle side to change the mould. With the piggyback arrangement, units can be angled above the main unit. This method saves floor space

like the vertical method but requires less ceiling height. The additional unit can be moved in two ways: attached to the main unit but with the nozzles thermally separated or with a separate cylinder which moves separately from the main cylinder.

5.1.2 Plastication Design In terms of the injection screw configurations within the injection units, these tend to have become standardised at 22D. This refers to the ratio of screw length (L) to its diameter (D), the L/D ratio. For faster production and high quality mixing this is often increased up to 26D. Specialised screws for hygroscopic materials, which enable venting, screws for increased mixing of materials, and configurations for temperature sensitive materials such as PVC, are all commonly available from suppliers.

5.1.3 Machine Type When robots are required to control insertion and removal of parts, machinery design can be an issue. The use of tie-barless machines as opposed to the conventional tie bar models is a contentious subject with advantages and disadvantages inherent in both machinery designs. However, when it comes to multimaterial technology, tie-barless machines can offer distinct advantages in the ease of utilisation of robots and the larger mould mounting area these machines offer. Often, this can mean a smaller capital outlay on machinery as a smaller machine may be purchased.

Figure 17 Possible arrangements of injection units: (a) vertical and piggy back (side view) and (b) parallel and right-angled (overhead view)

23

Multi-Material Injection Moulding

Now machinery issues have been briefly overviewed, individual technologies for multi-shot will be introduced. These are: • • •

are used to control blocking and opening the cavity to particular material feeds. For example, a two component process such as shown in Figure 18 may consist of the following stages:

Core back moulding Rotating tool moulding Transfer moulding.

1. The first material is injected into the cavity 2. Using a core puller to activate a slide seal, a further area of cavity is revealed

5.2 Core Back Moulding 3. The second material is injected into the cavity Also referred to in various literatures as composite injection moulding or multi-shot. The manufacturer Battenfeld uses the trade name Combiform for this process. Core back is a tooling controlled process.

4. The completed multi-shot component is ejected.

Core back moulding, thought of simplistically, is one tool taking multiple shots within a single machine cycle. It allows different areas of the tooling to be opened or closed to specific material feeds. This is achieved through the use of moving slides or inserts and is illustrated in Figure 18.

The ability to complete the process without mould opening or pre-form transport are the main advantages to this method when compared to other multi-shot techniques. However, increasing the number of components beyond two will certainly significantly increase the cost of tooling due to the increased intricacy required. The machine must also have the necessary means to activate all the slides in the tooling.

In the left hand diagram in Figure 18, the insert is closed. This prevents the first injected material from entering this area of the cavity. When the insert is opened, as shown in the right hand diagram, the second material can feed into the newly opened cavity area and flow into the material already injected to give the multi-shot component. In this way slides and inserts

As in all multi-material injection, attention must be paid to the compatibility of the melts. The use of the core back technique enables greater bond strengths to be achieved than in other multi-shot techniques as the time between injection of the first melt and injection of the second material can be optimised. However, the sequence of injection of the first material then the

Figure 18 Core back moulding technique

24

Multi-Material Injection Moulding

second material is longer than in other multi-shot techniques, which proceed in parallel. Therefore in components whose design lends it to both techniques, a detailed analysis of the economic implications of the process routes may be required to determine the most appropriate method of production.

expensive tooling. A rotary platen must have an accurate indexing device to control the rotation and the stroke needs to be both fast and cushioned to prevent damage. The platen must also have the facility to mount ejector pins. An example of a tool is shown in Figure 19.

However, for some parts other methods may be inappropriate. This could be due to either tooling costs, especially on large parts, or to the nature of the material. For example robotic transfer of a very flexible material may be difficult. Other important factors may be cycle times, for example the cooling times may be very short on a thin moulding. In cases such as these, a core back tooling system may be the best option.

The process proceeds in parallel so at any stage there is a shot being injected into each cavity. This makes the overall cycle time per moulding shorter than the core back technique described earlier. Generally the moulding produced in the first cycle should be expected to melt only on the very surface. This gives the good material separation required but still forms an adequate bond. This does however require good control of the process.

5.3 Rotating Tool Moulding

5.4 Transfer Moulding

In this method, the mould rotates through 180° for a two-shot part or 120° for a three-shot part. Rotational capability can be machine or tool based. There can be an integral rotary capability designed into the tool such as in Figure 19 or the machine can be equipped with a rotary attachment to the moving platen as in Figure 20. The choice usually comes down to economics. If rotational capability is to be used regularly it is cheaper to have it on the machine, than to continually buy more

In this method, instead of rotating the mould, a robot is used to transfer the moulding to the next cavity where it can then be over-moulded. This is shown in Figure 21. In this example the robot will move the upper moulding to the lower larger cavity as the tool opens after each cycle. Like rotary methods, moulding proceeds in parallel, with a moulding produced in each of the cavities during any cycle. Therefore the cycle time will be dependent on the moulding requiring the

Figure 19 Rotary table tool (Reproduced with permission from Burnett Polymer Engineering)

25

Multi-Material Injection Moulding

Figure 20 Indexing plate tool (Reproduced with permission from Burnett Polymer Engineering)

Figure 21 Transfer tool (Reproduced with permission from Burnett Polymer Engineering)

longest moulding time. As in rotating methods, a good bond is required whilst maintaining distinct separation of materials. High accuracy is required in placing the insert to get good definition and registration on the final component. A means must therefore exist to hold the pre-form accurately in place before the second material is injected onto it.

valve is switched within the mould to expand the cavity and then the rest of the shot is injected to create a multishot component.

Transfer moulding is not restricted to one machine. Robotics can be used to move the pre-form to a second machine. However, this would involve investment in both another machine and a second injection tool. If multiple layers are required however, this can be used for example, to produce a four layer moulding: two layers are formed in one machine prior to robotic transfer to a second machine where two further layers can be added.

This section will introduce material selection issues for multi-shot as well as providing some introductory information on two classes of materials which may not be familiar to the non-specialist moulder, namely thermoplastic elastomers (TPE) and liquid silicone rubbers (LSR).

5.5 Multi-Shot with a Single Injection Unit The mono-sandwich technique for co-injection moulding was described in Section 4.1.4 to which the reader should refer for machinery details. This technique can also be used for over-moulding by using the core back technique, again described earlier. In this technique termed the monosandwich 5 process (154), ‘an additional value is required in the runner system that can release different valves as necessary’. Once the melt is layered, the first component is injected. The

26

5.6 Material Selection for Multi-Shot

5.6.1 Material Properties Tables of compatibility have already been introduced, such as the one shown in Table 1. These describe material miscibility and therefore likely adhesion. Possible modifications may be considered through alloying or the addition of compatibilisers. The thermal properties are also important particularly both softening and melting temperatures and ranges. This is due to the requirement for limited melting to form a bond, whilst ensuring that the individual materials are clearly separated. Moulding machine variables will affect this, through changes to melt and

Multi-Material Injection Moulding

mould temperature and injection speed. The molten contact time will drastically affect the final bond strength and the separation achieved. If the first shot becomes molten at too deep a layer, it will flow when the second material is injected onto it. This may also influence decisions as to what type of multi-shot technique can be best employed. The testing of bond strength can be achieved by peel testing or by standard tension testing as required.

both Germany (65) and the UK (a.5) and is likely to hit commercial exploitation in the near future.

5.6.2 Material Process Order

Thermoset flexible/rigid combinations can be achieved by combining liquid silicone rubber with thermosets. The similar processing temperature requirements and process control is much enhanced with this combination, providing that the mould is designed with adequate consideration of flows.

The melting and softening characteristics have been mentioned already. They also affect the potential process order. Since the material injected first is already well on its way to cooling when the second material is injected, it is better to mould the material with the lowest melting temperature first rather than visa-versa. This is where one technique may become more preferable over another for certain material combinations. For example, core back moulding can use less than a full cycle between material injection. This means injection of the second component can occur before full cooling has taken place, therefore increasing the potential to achieve adhesion in some cases. This is not possible with the rotary tool or transfer methods.

5.6.3 Using Thermoset Materials The use of thermoplastic/thermoset combinations is a further area of development (65, 85). There are two possibilities for this process. 1. The thermoplastic is moulded and placed in the thermoset mould. 2. The thermoset is moulded and cured and placed in a thermoplastic mould. With the first of these processes, the choice of thermoplastic will be very dependent on the temperature required in the thermoset mould. If high cure temperatures are required very few materials may be suitable. With route 2, it may prove difficult to achieve a bond between a fully cured thermoset and the molten thermoplastic, as there will be no interdiffusion. However, clever design, making use of both material properties such as shrinkage, and tooling to promote mechanical interlock, may remove the need for adhesion. This is an area of ongoing development in

The core back technique offers increased opportunity to obtain adhesion between materials. This route would allow the thermoplastic to contact the thermoset before the part has fully cured. This, however, presents problems of its own as controlling the mould temperature and the differing thermoset/thermoplastic flow fronts would be extremely difficult.

5.6.4 Liquid Silicone Rubber (LSR) Liquid silicone rubber can also be combined with some thermoplastics and this is an area of much commercial interest. One current application is automotive: General Motors produce a thermoplastic/ LSR multi-shot air intake manifold on the Northstar model (a.6). There are numerous examples of work in this area (108, 121, 125, 132, 146, 147, 151, 189) with potential applications including shower heads and water resistant mobile phones. The reason for the interest is the added versatility offered by soft/hard combinations using LSR. LSR materials are thermally stable showing little change in properties with temperature. This can be of special interest at elevated temperatures where the use of TPEs may become limited. LSRs also have rapid cure cycles, and, because post cure is not necessary, finished parts cost less than other thermoset technologies. Injection mouldable grades are formulated as twocomponent systems and cure at temperatures of around 170-230 °C (6). Like moulding with thermoplastic materials, the cycle times are part dependent. Cycle times of 15-60 s are typical. Because mix-meter pump systems are used to feed the injection machines, raw material handling of LSR materials is relatively simple.

5.6.5 Thermoplastic Elastomers (TPEs) The properties of thermoplastic elastomers that have made them so commercially successful are their low

27

Multi-Material Injection Moulding

modulus and flexibility. The ability to recover from stress and return to their original shape makes them suitable for applications such as sealing rings. These are the traditional markets for thermosetting rubber materials, which TPE materials are now replacing. TPEs have the added advantage of recyclability over thermoset materials, especially important in markets where environmental legislation is in place. Whilst newer material types have emerged in recent years, primary TPE types can be categorised into two generic classes, block copolymers (styrenics, copolyesters, polyurethanes and polyamides) or thermoplastic/elastomer blends and alloys (thermoplastic polyolefins and thermoplastic vulcanisates). These TPE types are known as two-phase systems as, essentially, a hard thermoplastic phase is coupled mechanically or chemically with a soft elastomer phase. The result is a TPE that has the combined properties of the two phases.

Durometer using a Shore Hardness scale. TPEs tend to be rated on a Shore A scale, the softest materials ranging from around 3 Shore A and the hardest to 95 Shore A. Out of interest, thermoplastic materials are measured on a different, Shore D scale. This gives an indicator of the difference in their hardness properties. TPE material grades are available with a range of hardness levels, however it must be considered that hardness is also a function of the thickness of the material and the substrate beneath. In multi-shot applications, the thinner the layer of elastomer on the substrate the harder it will feel due to the effect of the harder substrate beneath it. It is for this reason that standards such as ASTM specify a material thickness of 0.250 inches. The compression set is often specified for sealing type applications and is a measure of the deformation after compression for a specified deformation, time and temperature. The usual test method is ASTM D395 or ISO 815, which calls for a 25% deformation.

Thermoplastic elastomer usage has increased significantly in recent years and is expected to continue to rise. Worldwide consumption was estimated at 1,400,000 metric tonnes per year in 2000. Some examples of common thermoplastic elastomers are shown in Table 4. As well as adhesion considerations, the suitability of a TPE will also depend on properties such as its hardness and compression ratio. Hardness can be defined as the resistance of the material to indentation and is usually measured on a

5.7 Multi-Shot Moulding Applications Case Studies 5.7.1 Trio Knob An interesting example of a relatively early UK multishot application (285) from Sifam, now SMT multishot, Devon, England, details the cost savings that can be achieved using multi-shot technology. The original costings are from 1996, but the relative savings

Table 4 Examples of TPEs and substrates Type

Elastomer description

Sub-group

Possible substrates

TPE-O

Polyolefin blends

PP/EPDM PP/EPDM crosslinked

PP PA (modified)

TPE-V

Polyolefin alloys

Various

PS, ABS, PET, ASA, ABS/PC blends

TPE-S

Styrene

SEBS SBS SEBS/PPE

PP PA (modified)

TPE-A

Polyamide

PA 12 based PA 6 based

PA

TPE-E

Polyester

Polyesterester Polyetherester

PA - poyesterester only, PET, PBT

TPE-U

Polyurethane

Polyester urethane Polyether ester urethane Polyether urethane

PA, ABS, POM, PC, PBT, PVC

28

Multi-Material Injection Moulding

Table 5 Run cost comparison for Trio knobs (285) Production method

Traditional

2-Shot

3-Shot

Tool cost

£8,500

£12,000

£19,000

Cycle time (secs)

21 + 21

21

21

Machine cost (100,000 pieces)

£1,241

£657

£695

Materials

£345

£365

£385

Assembly/print

£1,650

£825

£0

Job cost

£3,236

£1,847

£1,080

involved are still applicable today. The three production methods are as follows: •

traditional: moulding two components, (a knob and a coloured cap), assembly and printing

•

2-shot: knob and cap moulded together, eliminates assembly, still requires printing

•

3-shot: part re-designed so that print effects are instead moulded in, thereby eliminates assembly and printing

It can be seen from Table 5 that despite the major increase in tooling costs switching to 3-shot reduced job cost due to the following factors:

manufacture screwdriver handles (107). A nylon core is used over which two different coloured layers of polyphenylene ether (PPE) are then moulded. These layers give the final part both aesthetic appeal and commercial branding. Finally, a TPE is added for a soft feel grip. Adhesion is achieved in the layers by clever use of material properties and tooling design, to achieve bonding through mechanical interlock. This imaginative design results in an incredibly strong component giving improved impact resistance and torque. An application of this type requires extreme accuracy in location of the various components, to keep definition of the end product and to avoid damage to the tooling. This product highlights what can be achieved with successful collaboration between manufacturer, moulder and machinery supplier.

5.8 Limitations to Multi-Shot Moulding •

Utilising only one injection machine instead of two

•

Keeping the cycle time the same due to sequential moulding whereby the three cavities are each moulding at any one cycle

•

Removal of assembly and printing costs.

Moulding was carried out using a three-cavity tool moving the rotating side of the mould tool by 120° after each injection cycle. At any one stage there are three mouldings in the tool; a first single shot, a two shot intermediate moulding and a complete three shot component which is then ejected. Since all three cavities fill simultaneously, cycle time is fixed to the cavity requiring the longest fill time.

5.7.2 Stanley Screwdriver Stanley Tools, Engel and Burnett Polymer Engineering, Northampton, UK developed a 4-shot process to

Perhaps the most important issue with regard to multishot moulding is the cost of tooling. Obviously this varies depending on the part design and the complexity of tooling required. More complex rotating mould tools may also be more prone to breakdown than standard tools. Another problem associated with tooling concerns machine sizes. Over-dimensional, bulky moulds require larger machines, increasing machine costs and requiring a larger space due to the larger machine footprint. One way around this is to use tie-bar-less machines, the advantages of this machine configuration in relation to multi-shot have already been discussed. The use of two injection machines in a transfer process also involves high investment as two machines and tools are required. Accurate positioning of the mould cavities must also be achieved. Moving and rotating the tool to achieve precision positioning of parts, often at very high speeds to optimise cycle times, can create wear and inaccurate registration. This also places restrictions on cycle times due to the time required to carry out this change of positioning.

29

Multi-Material Injection Moulding

In methods using the same mould and multiple cavities, process restrictions may limit bonding strength when multiple materials are employed, since only one tool temperature can be employed The choice of tool temperature may be compromised from what would be the optimised bonding temperature.

6 Over-Moulding In this process, a component termed a preform is placed into the tool of an injection moulding machine. A second material is then moulded onto or around the preform. Two methods fall under this category: insert moulding and lost core moulding.

6.1 Insert Moulding Insert moulding (94) with plastics is a two-step process whereby a first preform component is placed into the open mould cavity. Injection then proceeds as with traditional moulding methods with injection of a molten plastic onto the preform. This is illustrated in Figure 22. This process is not limited to two material components and the resultant mouldings can be transferred in this way until the required number of layers is achieved.

Inserts can be loaded by hand as shown in Figure 22 or by the use of robots. Inserts must be accurate in both their dimension and their placement into the overmoulding tool to prevent tool damage and provide accurate registration of one material on another. A means must also exist to hold them in place within the tool. In this way it has similar requirements to that of in-mould lamination techniques commonly used to decorate plastics with films or foils which can be found in a specialist Review Report (a.7) and will not be covered further here.

6.2 Lost Core Moulding The lost core technique, like insert moulding, is often used in combination with metals as well as plastics. It produces a hollow component similar to those produced by techniques such as extrusion blow moulding or gas assisted injection moulding. This technique overcomes disadvantages inherent in both these processes. It enables high dimensional accuracy unlike extrusion blow moulding, as well as a defined interior surface not possible with gas-assisted injection moulding. For the manufacture of plastic components, the core is first produced either from a low melting metal alloy, usually tin-bismuth, or a soluble plastic material (377). The core is then inserted, either by hand or robot, into a

Figure 22 Insert moulding (Reproduced with permission from Burnett Polymer Engineering)

30

Multi-Material Injection Moulding

Table 6 Process attributes of lost-core moulding Advantages

Disadvantages

Mould design relatively simple

Expensive

Complex geometry possible

High unit cost

High quality surface finish

Long development times

Good , seam–free interior surface

Core materials can be expensive

Weight saving High cavity pressures permissible

tool and over-moulded. The core material can then be melted or dissolved out and the final component cleaned of any residual waste material. There are advantages and disadvantages with this technique. These are detailed in Table 6. Applications for this technology include nylon air inlet manifolds for car engines (312), canoe paddles, tennis rackets, BMX bike wheels and hot water heating pumps.

7 The Future? A variety of multi-material injection moulding variations exist. Some have been described here, others are beyond the scope of this review which has concentrated on plastic material moulding only. It is likely that in the future, commercially successful moulders will require both the understanding and adaptability to utilise a wide range of these process options. It is also likely that developments will continue to extend beyond the use of just plastic materials. Future components may be hybrids of many different materials such as plastics, metals and ceramics all created as a single component. Tooling costs will be key to future developments in this area, due to the prohibitive costs often involved in tooling for multiple materials. Developments in both the mouldability and adhesion characteristics of both thermoset and thermoplastic materials, and machinery enhancements in terms of enhanced speeds and control, are likely to further enhance processing and material combination options. With such possibility inherent in these processes it is likely that the future limitations on this technology may extend only to the limits of the imaginations of designers.

Additional References a.1

R. Garcia-Etxabe, J.J. Campo, J.C. Manchado, R. Clemente, Application of Co-injection Technology to Handles for the Gear Lever, Injection Moulding 2002, 18-19 March 2002, Barcelona, Spain.

a.2

J.C. Love, G.F. Smith, M.W. Pharoah, In Mould Painting using Granular Injected Paint Technology, Injection Moulding 2002, 18-19 March 2002, Barcelona, Spain.

a.3

R. Seldon, Journal of Injection Moulding Technology, 1997, 1, 4, 192.

a.4

Arburg, Technical Information, Multi Component Injection Moulding, 522771-GB08/1999.

a.5

G.F. Smith, Warwick Manufacturing Group, The University of Warwick, personal communication.

a.6

K. Baraw, The northstar air intake manifold. Conversion from metal to plastics, Proceedings of the Annual Conference, Composites Institute, Society of the Plastics Industry, 1997, S. 15-C/1.

a.7

J.C. Love and V. Goodship, In-Mould Decoration of Plastics, Rapra Review Report, 2002, 13, Issue 146.

31

Multi-Material Injection Moulding

Abbreviation and Acronyms ABS

acrylonitrile-butadiene-styrene terpolymer

ASA

thermoplastic copolymer from acrylonitrile, styrene and acrylates

CLTE

coefficient of linear thermal expansion

D

diameter

EMI

electromagnetic interference shielding

EPDM

ethylene propylene diene terpolymer

EU

European Union

EVA

ethylene-vinyl acetate copolymer

L

length

LSR

liquid silicone rubber

MFI

melt flow index

PA6

polyamide 6

PA 66

polyamide 66

PBT

polybutylene terephthalate

PC

polycarbonate

PE-HD

high density polyethylene

PE-LD

low density polyethylene

PET

polyethylene terephthalate

PMMA

polymethyl methacrylate

POM

polyoxymethylene

PP

polypropylene

PPE

polyphenylene ether

PPO mod

modified polyphenylene oxide

PS-GP

general purpose polystyrene

PS-HI

high impact polystyrene

SAN

styrene-acrylonitrile copolymer

TPE

thermoplastic elastomer

TPE-O

polyolefin blends thermoplastic elastomer

TPE-V

polyolefin alloys thermoplastic elastomer

TPO

thermoplastic olefin elastomer

TPU

thermoplastic polyurethane

32

References and Abstracts

Abstracts from the Polymer Library Database Item 1 Plastiques & Elastomeres Magazine 53, No.5, June/July 2001, p.25-7 French HOT RUNNER MOULD Lobers H; Moritz M Unitemp An account is given of the structure and mode of operation of a hot runner mould manufactured by Muller Modellund Formenbau using a hot runner system developed by Unitemp. The application of this mould in the sequential injection moulding of a talc filled PP car component by Plastic Omnium is examined. PEUGEOT SA; MULLER MODELL- UND FORMENBAU; PLASTIC OMNIUM SA EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; GERMANY; SWITZERLAND; WESTERN EUROPE

Accession no.842610 Item 2 Revue Generale des Caoutchoucs et Plastiques 78, No.796, June/July 2001, p.40-5 French INJECTION MOULDING OF TECHNICAL PARTS: FOUR PROCESSES UNDER EXAMINATION Delannoy G An examination is made of developments in four recently introduced plastics injection moulding processes, including sequential, two-material/multi-material and water-assisted injection moulding and the MuCell process developed by Trexel for the injection moulding of microcellular products using supercritical gases as blowing agents. Types of polymers processed and products manufactured by these techniques are reviewed. TREXEL USA; WORLD

Accession no.842593 Item 3 Revue Generale des Caoutchoucs et Plastiques 78, No.796, June/July 2001, p.36-7 French INJECTION PRESSES: DEMAG PLAYS TO WIN Forest J P The activities of Demag in the manufacture of injection moulding machines are examined, and factors which have increased the success of Demag France on the French market are reviewed. Turnover and employment figures are presented, and details are given of the locations of the three production sites operated by the Demag Ergotech Group. Developments by Demag in

© Copyright 2002 Rapra Technology Limited

electrohydraulic presses and machinery for multicomponent moulding are described. DEMAG; DEMAG ERGOTECH; DEMAG FRANCE; MANNESMANN PLASTICS MACHINERY GROUP CHINA; EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; GERMANY; WESTERN EUROPE

Accession no.842592 Item 4 Macplas International Sept.2001, p.99/101 SEQUENTIAL INJECTION FOR FAMILY MOULDS Bertacchi G; Pipino A; Boero G Plastic & Computer; Fiat Research Center This article illustrates the results of the first part of a project investigating the area of major interest for sequentially-operated injection moulding valve gates, followed by the development of a procedure for their implementation in family moulds applied to very dissimilar parts. Section headings include: problem analysis, methodology, experimental mould and moulding conditions, moulding and results, conclusion, and bibliography. 5 refs. SANDRETTO EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.842464 Item 5 European Rubber Journal 184, No.2, Feb.2002, p.16-7 CO-MOULDING WITH LSR Haberstroh E; Lettowsky C IKV Aachen The increased application of multi-component injection moulding in combination with new materials such as thermoplastic elastomers and liquid silicone rubber opens up a multitude of new products which can be manufactured with fewer processing steps. Heat-cured LSR can be co-moulded and offers a lot of advantages over a TPE in terms of its thermal properties and physiological response. Like all over-moulding applications, overmoulding of LSR onto thermoplastic substrates demands a good adhesion between the two materials. The objective of this project was to determine and to evaluate the influence of machine parameters and of process parameters, as well as of part design and mould design, on the adhesive strength of selected material combinations. 12 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.842346

33

References and Abstracts

Item 6 Shawbury, Rapra Technology Ltd., 2001, pp.165. 29 cms. Rapra Review Rept. No. 137, vol. 12, No. 5, 2001. 4/1/02 SILICONE ELASTOMERS Jerschow P Wacker-Chemie GmbH Edited by: Ward S (Rapra Technology Ltd.) Rapra.Review Rept. No. 137

surface skin layer, a transition layer and an inner core layer was observed. The simulation software package Moldflow MPI was used to identify the thermal and shear histories of the polymer melt during the injection moulding process. The characterisation of each layer and its dependence on the thermal and shear histories are discussed. The influence of the shear and thermal histories during injection moulding on the beta-phase formation of injection-moulded PP is considered. 11 refs. SOLVAY

This review report on silicone elastomers devotes chapters to the following topics: the silicone elastomers market; applications; composition and function; room temperature vulcanising silicone elastomers, liquid silicone rubber, solid silicone rubber, and the processing of silicone elastomers. 465 refs.

AUSTRALIA

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.841124 Item 7 Journal of Injection Molding Technology 5, No.3, Sept.2001, p.160-79 SPECIAL AND EMERGING INJECTION MOLDING PROCESSES Lih-Sheng Turng Wisconsin-Madison,University A general review is presented of several special and emerging injection moulding processes, covering coinjection moulding, fusible core injection moulding, gasassisted injection moulding, injection-compression moulding, in-mould decoration/lamination, low-pressure injection moulding, micro-injection moulding and microcellular injection moulding. Particular attention is paid to current state-of-the-art technology, applications, process physics, technical challenges and applicable materials. 83 refs. USA

Accession no.840082 Item 8 Journal of Injection Molding Technology 5, No.3, Sept.2001, p.133-40 CORRELATION BETWEEN MORPHOLOGY DISTRIBUTION OF INJECTION MOLDED POLYPROPYLENE AND PROCESSING HISTORY IDENTIFIED BY NUMERICAL SIMULATION Liu G; Edward G Monash,University The morphology distribution of injection-moulded PP (Solvay Eltex PHV252) observed using polarised optical microscopy was examined. A three-region-multilayer model was adequate to describe the skin-core morphology of these injection-moulded parts. In the fully developed flow region, a clear three-layer structure composed of a

34

Accession no.840079 Item 9 Rubber Bonding 2001. Conference Proceedings. Cologne, Germany, 20th-21st November 2001, Paper 12 MULTI-COMPONENT INJECTION MOULDING OF LIQUID SILICONE RUBBER/ THERMOPLASTIC COMBINATIONS Haberstroh E; Lettowsky C IKV (Rapra Technology Ltd.; European Rubber Journal) Increasing quality requirements and economic pressures are forcing more and more companies to look at the advantages of special injection moulding processes at a very early stage of the moulded part development process. The two-component injection moulding process allows the manufacture of parts consisting of two components which are arranged next to or above each other. Besides well known combinations of thermoplastics and thermoplastic elastomers (TPE), which are used in various applications, the combination of liquid silicone rubbers (LSR) and thermoplastics becomes more important due to their better mechanical and thermomechanical properties, as well as the chemical resistance in comparison with TPE. Combinations of LSR and polyamide can be a new alternative for combinations made of rubber and metal which often require a costly preparatory treatment. There is insufficient knowledge regarding the adhesive strength of these combinations, which depends on the properties of the materials, the process parameters in the moulding process and the moulding technique. To solve this, techniques are being developed to meet requirements. Results of investigations in this context are presented. 12 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.839862 Item 10 Injection Molding 9, No.11, Nov.2001, p.59-60 NEW TURNS FOR MULTICOMPONENT MOULD REVOLUTION Kirkland C; Neilley R Stack moulds that use a horizontal turning system to drive rotating core sets and core plates are drawing considerable

© Copyright 2002 Rapra Technology Limited

References and Abstracts

attention around the world from multicomponent moulders that want to lower part costs, and from monocomponent moulders that want to raise their bottom line. Ferromatik Milacron Europe, in conjunction with mouldmaker Foboha, has developed the Cube. Four identical core plates are mounted on a centre platen that rotates in the horizontal axis. A spinning-core stack mould designed and built by Gram Technology produces 24 juice bottle screw caps per cycle and runs at approximately 8 seconds. FOBOHA; FERROMATIK MILACRON; GRAM TECHNOLOGY WORLD

Accession no.839293 Item 11 Plastiques & Elastomeres Magazine 53, No.3, April 2001, p.34-5 French TWO FIRSTS AND A NEW CONCEPT AT PLASTIC OMNIUM Gouin F Thin-wall sequential injection moulding and film insert moulding techniques used by Plastic Omnium in the production of plastics parts for Renault’s Laguna II range of cars are described. PLASTIC OMNIUM SA; RENAULT SA; ATLANMOLD; AUDI AG; REXHAM CORP.; VOLKSWAGEN AG EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; GERMANY; USA; WESTERN EUROPE

Accession no.839065 Item 12 Kunststoffe Plast Europe 91, No.12, Dec.2001, p.12-5 English; German COINJECTION OF THERMOPLASTICS AND ELASTOMERS Lange C; Hungerkamp T Krauss-Maffei GmbH This article explains that the production of composites by coinjection moulding is state-of-the-art, with high-precision, modular injection moulding machines and innovative mould technology now allowing crosslinking elastomers to be injected in combination with thermoplastics. This article discusses the technical and economic aspects of this new coinjection technology. (Translated from Kunststoffe 91, No.12, Dec.2001, p.36/42). EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.838985 Item 13 Thermoset Topical Conference: Thermoset Technology for the Molder.

© Copyright 2002 Rapra Technology Limited

Research Triangle Park, NC., 12th-14th March 2001,p.77-88, 012 MULTIMATERIAL INJECTION MOLDING FOR THERMOSETS Timmerman J Engel Guelph (SPE,Thermoset Div.; SPE,Piedmont Coastal Section) Engel’s multimaterial moulding process, which combines several thermosets and thermoplastics into multifunctional assemblies in one manufacturing step or in one production cell, is discussed. Applications of the technology are considered and four variants of the method, i.e. the transfer method, rotary table method, index plate method and slide technique, are examined. Machinery available from Engel is described. CANADA; USA

Accession no.838255 Item 14 Thermoset Topical Conference: Thermoset Technology for the Molder. Research Triangle Park, NC., 12th-14th March 2001,p.33-9, 012 NEW AND BETTER PRODUCTS BY COMBINING THERMOSETTING RUBBER AND THERMOPLASTIC MATERIALS IN INJECTION MOLDING Hunold D Krauss Maffei (SPE,Thermoset Div.; SPE,Piedmont Coastal Section) The potential of multi-component injection moulding is discussed with reference to the possibilities of combining not only thermoplastics and thermoplastics but also thermosets and thermoplastics or thermosets and rubber. Some of the problems expected when combining thermosets and thermoplastics or thermosets and rubbers are listed. The basic flow properties are considered, TS analysis is outlined and the production of a pan handle is described. 2 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; USA; WESTERN EUROPE

Accession no.838251 Item 15 Plastics Technology 47, No.12, Dec.2001, p.29-31 COINJECTION’S NEW LOOK: TWO SCREWS, ONE BARREL Knights M The process and advantages of coinjection moulding are explained, but the disadvantages of machinery costs and complexity are also highlighted. To overcome these obstacles, Community Products of the USA has developed a new coinjection technology, and a new division, Twinshot Technologies, has been formed to market the patent-pending process. This article looks in detail at the company’s development.

35

References and Abstracts

COMMUNITY PRODUCTS; TWINSHOT TECHNOLOGIES USA

Accession no.836806 Item 16 Revue Generale des Caoutchoucs et Plastiques 78, No.795, May 2001, p.48-53 French INNOVATION AT THE HEART OF PROCESSES Biron M Developments in techniques for rubber processing are examined with reference to the microwave vulcanisation of profiles and coextrusion and coinjection moulding processes for the production of components combining plastics with thermoplastic elastomers or vulcanisable rubbers. An examination is made of thermoplastic elastomer (TPE) grades developed by a number of companies to meet requirements for direct adhesion to plastics, and data are presented for TPE and rubber adhesion to various thermoplastics. The influence of processing, post curing and storage conditions and part thickness on the volatile content of silicone rubber vulcanisates is also discussed. MES; SAIREM EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; WESTERN EUROPE

Accession no.835468 Item 17 Macplas 25, No.224, Dec.2000, p.54-6 Italian HOT RUNNER SYSTEMS FOR MULTICOMPONENT INJECTION MOULDING Gauler K Incoe International Inc. Hot runner systems and their use in two-material, twocolour, multi-material and multi-colour injection moulding are examined. Examples are presented of products manufactured by these processes and combining plastics and thermoplastic elastomers. USA

Accession no.835455 Item 18 Industria della Gomma 45, No.1, Jan./Feb.2001, p.40-4 Italian INJECTION MOULDED MULTI-MATERIAL PRODUCTS Developments by Arburg in machinery for two-, threeand four-material/colour injection moulding are reviewed. Technical features of the Allrounder C and Allrounder S

36

series of presses and the associated Selogica computer control system are described. ARBURG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.835426 Item 19 Plast’ 21 No.102, May 2001, p.97-8 Spanish INJECTION MOULDING, A DRIVING FORCE FOR CHANGES Netstal Maschinen AG Injection moulding processes and machinery for the production of plastics packaging containers are examined. Developments by Netstal in its SynErgy range of injection presses for use in this sector are described, with particular reference to in-mould labelling systems and machines for multi-material moulding. SWITZERLAND; WESTERN EUROPE

Accession no.835423 Item 20 TPE 2001. Conference proceedings. Brussels, Belgium, 18th-19th June 2001, Paper 10 TOOL DEVELOPMENT FOR 2K-TPE COMPONENTS FOR THE AUTOMOTIVE INDUSTRY USING 3D SIMULATION Kallien L H; Menchen M SIGMA Engineering GmbH; Beckunbach GmbH (Rapra Technology Ltd.; European Plastics News; Plastics & Rubber Weekly) The application of 3D numerical simulation on TPE components for automotive applications is described. One of the products is used as a sealing system for a outstanding light seal for the BMW E39. The TPE component is injected onto a PP structure using the 2K injection moulding method. Within this technology, two different materials are injected into one die, providing perfect functionality together with best possible productivity. The second part is a metal door lock part, which is overmoulded by TPE. The use of numerical simulation is described and the simulation results against real life experiments are compared. 7 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.835023 Item 21 Kunststoffe Plast Europe 91, No.10, Oct. 2001, p.37-8 MULTI-MATERIAL MOULD WITH ROTARY MECHANISM Keusgen H Braun Formenbau GmbH

© Copyright 2002 Rapra Technology Limited

References and Abstracts

The design of a 16 + 16-cavity injection mould for the manufacture of a two-material base of a housing for a powder inhalation system for dispensing high-potency medications is described together with a rotary indexing mechanism for the mould, both of which guarantee short cycle times. (Kunstoffe, 91, No.10, 2001, p.127-30) EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.834967 Item 22 Kunststoffe Plast Europe 91, No.10, Oct. 2001, p.23-5 COMBINATIONS ENHANCE PERFORMANCE MANY TIMES OVER Jaeger A Demag Ergotech GmbH Trends in materials and applications, mould technology, machine technology and process engineering relating to multi-component injection moulding are discussed. Possible combinations of materials for multi-component injection moulding are indicated. (Kunstoffe, 91, No.10, 2001, p.91-4) EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.834961 Item 23 Plastics and Rubber Weekly 9th Nov.2001, p.15 BOOST FOR MOULDERS Smith C An innovative coinjection moulding technology enables a conventional single-screw injection moulding machine to produce sandwich moulded parts at minimal additional cost. Twinshot Technologies has replaced the conventional screw and barrel with a two-part plasticising system, comprising one screw running within another. A simple spring-loaded friction clutch provides a connection between the two screws, while a modified check valve nozzle manages the flow into the mould. The system is claimed to provide a low-cost way to produce sandwich mouldings using regrind or structural foam as the core material. TWINSHOT TECHNOLOGIES USA

Accession no.834616 Item 24 Macplas International May 2001, p.58 DUAL-INJECTED CHAIRS This article fully describes the “RMP Ecologica” dual injection moulding machine from MIR, which was used recently to produce garden chairs moulded with UV-

© Copyright 2002 Rapra Technology Limited

stabilised polyolefins featuring thermoplastic elastomer inserts shaped like the traditional cord or straw weaving of classic-style chairs. MIR EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.832543 Item 25 Plastics, Rubber and Composites 30, No.1, 2001, p.11-5 INTERFACIAL INSTABILITIES IN MULTIMATERIAL CO-INJECTION MOULDINGS. I. BACKGROUND AND INITIAL EXPERIMENTS Goodship V; Kirwan K Warwick,University Interfacial adhesion between the skin and core is vital for successful co-injection moulding. This is the first paper in a series, which introduces and describes an in-mould method of mixing that is applicable regardless of the compatibility of the materials. It works by inducing turbulent mixing at the interface between the skin and core materials. It makes use of the change that occurs from laminar to turbulent flow at high injection speeds in co-injection moulding. This novel approach takes advantage of the moulding parameters already available within the co-injection system to offer an expanded range of material combinations for multi-material moulding. Comparisons are made between multi-material mouldings made with miscible polymers, immiscible polymers with no compatibiliser, and immiscible polymers bonded by compatibilisers. 11 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.831699 Item 26 Northbrook, Il., c. 2001, pp.26. 27 cms. 11/9/01 ROGAN AN EXTRAORDINARY SENSE OF TOUCH Rogan Corp. Pure Touch products from Rogan are described. They are reported to offer the latest in thermoplastic elastomer technology, providing aesthetics with ergonomics in products such as knobs, grips, and handles. The company provides multi-material injection moulding expertise which features multi-material, multi-colour and texture combinations. The product range is described and illustrated and dimensions are given. USA

Accession no.831568 Item 27 Plast’ 21 No.102, May 2001, p.43-4

37

References and Abstracts

Spanish MULTI-MATERIAL INJECTION MOULDING FROM OIMA Developments by Oima in its Stratos range of presses for two-material, two-colour, multi-material and multi-colour injection moulding are reviewed. OIMA SPA; TECNOPRES SL EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; SPAIN; WESTERN EUROPE

Accession no.831355 Item 28 Plast’ 21 No.102, May 2001, p.29-30 Spanish MULTI-COMPONENT INJECTION MOULDING: AN OPPORTUNITY FOR IMPROVEMENT Two-material and multi-material injection moulding processes are described, and their advantages in terms of reduced production costs and increased productivity are examined. Industrial sectors which make use of plastics components produced by these processes are also reviewed. BM BIRAGHI; CENTROTECNICA SA; OIMA SPA; TECNOPRES SL; MIR SPA; IMVOLCA EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; SPAIN; WESTERN EUROPE

Accession no.831351 Item 29 Plast’ 21 No.102, May 2001, p.20-1 Spanish SAVING MONEY, TIME AND SPACE Details are given of the PlugXPress system developed by Windsor Kunststofftechnologie for retrofitting injection presses for multi-material moulding. WINDSOR KUNSTSTOFFTECHNOLOGIE GMBH; ITALPRENSAS SANDRETTO SA EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; SPAIN; WESTERN EUROPE

Accession no.831349 Item 30 POLYPROPYLENE IN PACKAGING. Proceedings of a one-day seminar, held Shawbury, 25th June 1998. Shawbury, 1998, Paper 2, pp.6. 012 GIVING AN ADDED DIMENSION TO POLYPROPYLENE PACKAGING WITH ENGINEERED THERMOPLASTIC ELASTOMERS MacLarty R G Advanced Elastomer Systems (Rapra Technology Ltd.) It is shown that by combining the properties of engineered thermoplastic elastomers and rigid thermoplastic with the

38

multi-function injection moulding process methods, innovative parts can be developed. Part designers can capitalise on the advantages of both rigid and flexible materials in a single multifunctional component/system. This paper explores some of the process techniques available to the design engineer/processor, which use a combination of thermoplastic materials and multi-material injection moulding equipment, and examples are included of successful applications, which demonstrate the importance of the selection of the right grade of material from an ever increasing range of commercially available engineered thermoplastic elastomers. BELGIUM; EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.830718 Item 31 Injection Molding 9, No.9, Sept. 2001, p.12A-3A NEW TWIST ON MULTIMATERIAL MOULDING Neilley R The approach made by Hekuma GmbH, to multicomponent moulding is described. Hekuma’s system, which allows multi-component moulding with one moulding machine and eliminates the need for rotating platens and other complex additions, makes use of a twocomponent Netstal press, a standard stack mould and Hekuma’s own robotics to manipulate parts. The steps involved in the basic operation of this systems are outlined and the benefits of the system are considered. HEKUMA GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.830444 Item 32 Polimeri 22, No.2, 2001, p.45-54 Polish IMPROVED INJECTION MOULDING AT THE TURN OF THE MILLENNIUM. II. Johannaber F A description is given of coinjection moulding, multicomponent injection moulding and lost core injection moulding. 8 refs. EASTERN EUROPE; POLAND

Accession no.830395 Item 33 POLYMER PROCESSING ENGINEERING. 01. Proceedings of a conference held June 2001. London, IOM Communications Ltd., 2001, Paper 13, p.156-70, 012 MULTICOMPONENT LAMINATE MOULDING (MLM), A PROCESS FOR THE PRODUCTION OF MULTILAYER STRUCTURES IN INJECTION MOULDINGS

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Yasuda K; Allan P S; Bevis M J Asahi Chemical Co.Ltd.; Brunel University (Institute of Materials; Interdisciplinary Research Centre) The principles of multi-component laminate moulding, which permits the control of the laminate structure of two or more polymers moulded in combination, are outlined and the application of the technique to the manufacture of laminates from general purpose PS and HDPE is demonstrated. The results are also reported of the characteristics of the multi-component components, as determined by light microscopy, as well as their tensile and flexural properties. Comparisons are made with conventional injection mouldings of the two polymers. 16 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; JAPAN; UK; WESTERN EUROPE

Accession no.830366

Item 36 Modern Plastics International 31, No.9, Sept.2001, p.43/5 MODULAR MACHINES SUIT PROCESSORS AND OEMS Mapleston P Injection moulding machine makers face the challenge of providing presses tailored to purchasers’ specific needs while keeping their own production costs under control. This is spurring machine makers to boost modularity of design and cut options. Engel has introduced the Victory range of machines which will have around 360 options. By freely selecting and combining options, the machines can be customised to almost every standard application, the company claims. Windsor Kunstofftechnologie has found a way of retrofitting modularity. It introduced its add-on PlugXPress injection units at the beginning of last year, and recently added a small model to the range. WORLD

Item 34 POLYMER PROCESSING ENGINEERING. 01. Proceedings of a conference held June 2001. London, IOM Communications Ltd., 2001, Paper 12, p.121-55, 012 FLUID-ASSISTED INJECTION MOULDING Eckardt H Battenfeld GmbH (Institute of Materials; Interdisciplinary Research Centre) The main low pressure injection moulding techniques are covered, including the one-component structural foam process, multi-component injection moulding, Battenfeld’s MuCell process, gas-assisted injection moulding, water-assisted injection moulding (Aquamould), co-injection and Airmould Multifoam process, backmoulding processes, including in-mould decoration and textile backmoulding, and a combination of processes. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.830365 Item 35 British Plastics and Rubber Sept.2001, p.44/61 INJECTION MOULDING This article outlines injection moulding equipment on show at K2001. This includes machinery for liquid silicone rubber, microcellular foams, multi-material moulding, optical discs, PETP preforms, rubber moulding and BMC moulding. Electric, hydraulic and hybrid machines are described, together with robotics, tooling and control equipment. WORLD

Accession no.829743

© Copyright 2002 Rapra Technology Limited

Accession no.829708 Item 37 Medical Plastics 2000: Innovation, Opportunities and Challenges. Conference proceedings. Oakbrook, Il., 2nd-4th October 2000, p.195-7 MOULDING OF MICROSCOPIC MEDICAL COMPONENTS USING NANOMOULDING TECHNOLOGY Leopold A Murray Inc. (SPE) A plastic nanomoulding machine is used to mould parts and overmoulded features such as catheter tips directly to catheters. Challenges addressed include parts with gates less than 0.1 mm and wall thicknesses less than 0.05 mm. Moulding parts with volumes less than one cubic millimeter require very high pressure and fast injection times. New moulds with thermal cycling are sometimes required to bond plastics during overmoulding applications. USA

Accession no.829204 Item 38 Plastics for Portable and Wireless Electronics and Optical Applications. Conference proceedings. Charlotte, N.C., 23rd-24th October 2000, p.24-33 MOLDED INTERCONNECTED DEVICES Hartlmeier B MGS Mfg.Group Inc. (SPE) Details are given of MGS’ process for moulding interconnected devices (MID), which makes use of injection moulding with multi-shot applications. The materials are plated with a conductive element, and the

39

References and Abstracts

resultant plated materials can be electroless or electrolytic. Aspects covered include MID applications and benefits, plateable resins, conductors, multi-shot transportation methods, multi-shot transportation units and universal multi-shot systems.

designs and two-material, multi-material and gas-assisted injection moulding processes. EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN; WESTERN EUROPE

Accession no.828672

USA

Accession no.829150 Item 39 Journal of Polymer Engineering Vol.21, No.2-3, March-June 2001, p.303-18 LSR THERMOPLASTIC COMBINATION PARTS IN TWO-COMPONENT INJECTION MOULDING Haberstroh E; Ronnewinkel C Institut fuer Kunststoffverarbeitung The adhesion between liquid silicone rubber (LSR)/ thermoplastic (polyamide) combination parts produced by two-component injection moulding (overmoulding) was studied. The materials and moulds used were described, together with different test methods for determining the adhesive strength of the combinations. The results showed a good adhesive strength between polyamides and LSR. 17 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.828715 Item 40 Journal of Polymer Engineering Vol.21, No.2-3, March-June 2001, p.99-109 MICRO ASSEMBLY INJECTION MOULDING OF HYBRID MICROSYSTEMS Michaeli W; Rogalla A; Ziegmann C Institut fuer Kunststoffverarbeitung Microassembly injection moulding is derived from twocomponent injection moulding and overmoulding and it combines the positioned joining of inlay parts with the generation of functional microstructures. Studies were carried out on the production of movable microstructures using incompatible polymers, the production of fluidic hollow structures by lost core technology and the overmoulding of cylindrical structures such as wires and optical fibres. The results were discussed. 9 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.828700 Item 41 Plast’ 21 No.100, March 2001, p.53-5 Spanish OPTIMISATION OF THE INJECTION MOULDING PROCESS A review is made of some developments in plastics injection moulding technology, including modified screw

40

Item 42 NEW OPPORTUNITIES FOR THERMOPLASTIC ELASTOMERS. Proceedings of a one-day seminar held Shawbury, 19th April 1996. Shawbury, 1996, paper 3, pp.4. 012 ‘TPE MEETS ETP’. COMOULDING AND COEXTRUSION OF STYRENIC TPE’S WITH ENGINEERING THERMOPLASTICS Fraser D Evode Plastics Ltd. (Rapra Technology Ltd.) A range of thermoplastic elastomer compounds has been developed by Evode Plastics Ltd., which will bond to engineering thermoplastics such as nylon, ABS or polycarbonate using co- or insert moulding or coextrusion. The range, called Evoprene COGEE, based on Shell Chemicals’ Kraton G, is designed for a wide range of applications where TPE/PP combinations are unable to meet the requirements. Details are given of the grades of Evoprene COGEE available, their properties, processing considerations, and possible applications. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.827828 Item 43 Rubber to Metal Bonding. Proceedings of a one-day seminar held Shawbury, 30th January 1997.. Shawbury, 1997, paper 7, pp. 7. 012 INSERT MOULDING - AUTOMATIC MANUFACTURING OF RUBBER-TO-PLASTIC MOULDED COMPONENTS Arning M Engel Vertriebsgesellschaft mbH (Rapra Technology Ltd.) The automation of the production of rubber to metal and rubber to plastic moulded components is discussed, with reference to reducing production costs and improving productivity and quality. Basic features of Engel moulding machines which can assist in these aims are described, and include the use of FIFO-injection units, tiebarless machines, microprocessor-based process control, and the use of predictive software for predicting cure times, demoulding moments, and automatic control of the cure time for rubber to metal bonded parts. The use of peripheral equipment for an automated work cell for rubber to metal bonded products is examined, and examples are described of automated parts manufacturing. The Combimelt method of producing rubber to plastic bonded components is also detailed.

© Copyright 2002 Rapra Technology Limited

References and Abstracts

AUSTRIA; EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.827809 Item 44 BLOWING AGENTS AND FOAMING PROCESSES CONFERENCE 2001. Proceedings from a conference held Frankfurt, 13th-14th March 2001. Shawbury, Rapra Technology Ltd., 2001, Paper 8. 012 LOW PRESSURE INJECTION MOULDING Eckhart H Battenfeld GmbH (Rapra Technology Ltd.) A review is presented of the main low pressure injection moulding processes. The main aim of using low pressure injection moulding techniques is to fill the cavity at low cavity pressures, and so produce mouldings with low internal stresses. When using low pressure techniques, the holding pressure needed for conventional injection moulding to compensate volume shrinkage, can basically be eliminated, and the pressure necessary for compensation of volume contraction while cooling is achieved by means of a gas. One-component structural foam processes are described, followed by multicomponent injection moulding techniques, the Mucell process, gas-assisted injection moulding processes, including the Airmould process, and a combination of coinjection and Airmould techniques. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; UK; WESTERN EUROPE

Accession no.826079 Item 45 Antec 2001.Conference proceedings. Dallas, Texas, 6th-10th May, 2001, paper 298 EFFECT OF PROCESSING PARAMETERS ON BOND STRENGTH FOR MULTICOMPONENT INJECTION MOLDING Mehta S R; Parikh D R Advanced Elastomer Systems LP (SPE) The development of thermoplastic vulcanisates (TPVs), capable of bonding to thermoplastic substrates without the use of primer or adhesive is reviewed. The first materials were developed to bond to polyamide in the multicomponent injection moulding process. Subsequently, materials were developed that were capable of direct bonding to polyester or polyamide fibre, and the latest developments included TPVs capable of bonding to engineering plastics such as polycarbonate and ABS. Insert and two-component moulding is described. The influence of processing parameters on the bond strength between TPV and substrate was investigated, and for fibre-reinforced thermoplastics, it was established that high injection speed, and high mould and melt temperatures during the substrate moulding enhanced the

© Copyright 2002 Rapra Technology Limited

bond strength. This was attributed to the creation of a suitable surface for the subsequent TPV bonding. 6 refs. Accession no.825394 Item 46 Antec 2001.Conference proceedings. Dallas, Texas, 6th-10th May, 2001, paper 241 SUBSTITUTION OF METALLIC INSERT JOINTS BY TWO-SHOT-MOLDING Tome A; Ehrenstein G W Erlangen,Universitat (SPE) The moulding-in of a section of reinforced plastic in a non-reinforced plastic component by multicomponent injection moulding was evaluated as an alternative to the use of a metallic insert fitted after moulding, for joints assembled using standard screws. The performance of a moulded-in glass fibre reinforced polyamide boss in a non-reinforced polyamide part, joined using self-tapping screws, was compared with that of parts containing brass inserts fitted by hot-embedding and plastic inserts fitted by ultrasonic embedding, threaded M4 and M5. The static pull-out strength of the joints was comparable. 5 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.823740 Item 47 Antec 2001.Conference proceedings. Dallas, Texas, 6th-10th May, 2001, paper 232 SELF ADHESIVE LIQUID SILICONE RUBBERS (LSRS) FOR THE INJECTION MOLDING OF RIGID FLEXIBLE COMBINATIONS Bosshammer S; Henze E GE Bayer Silicones GmbH & Co.KG (SPE) Parts with rigid and flexible components may be produced by combining the injection moulding of a rigid thermoplastic part with the injection moulding of self-adhesive flexible silicone rubber. The liquid silicone rubber (LSR) is a two-component system, the silicone and crosslinker being stored separately and mixed at the injection mould machine. A test method for the measurement of adhesion strength was developed in which substrate sheets of thermoplastic or metal are overmoulded with the LSR, and the combination subjected to a peel test following vulcanisation. The method was evaluated using a LSR which was formulated to minimise adhesion to the mould, and its adhesion to glass fibre-reinforced polyamide-6, polyamide-6,6, and poly(phenylene sulphide), and to poly(butylene terephthalate) was determined. 6 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.823731

41

References and Abstracts

Item 48 Plastics News(USA) 13, No.6, 9th April 2001, p.4/34 JOHN DEERE GIVING NEW LAWN TRACTOR A SPIN Miel R John Deere is launching a new lawn tractor line using “spin steer technology” to allow the vehicles to turn on a dime. The company also enlisted moulders, toolmakers and engineers to rethink the design of the SST tractor. The result is a tractor that makes extensive use of PP from front to back. The sweeping hood incorporates a strategic SST logo to mask the site of the gate. Bemis Manufacturing used a proprietary mix of glass and mineral -filled PP to create a structural fender. A Milacron triplebarrel, coinjection moulding press was used to produce the steering wheel, which replaces the typical steel core with a structural plastic core. DEERE & CO.; DREYFUSS H.,ASSOCIATES; BEMIS MANUFACTURING CO. USA

Accession no.823175 Item 49 Antec 2001.Conference proceedings. Dallas, Texas, 6th-10th May, 2001, paper 150 NUMERICAL SIMULATION OF CO-INJECTION MOLDING Wang J Pou Chen Group; Pou Yen Technology (SPE) Computer aided engineering software was developed to simulate the co-injection moulding process in which two polymers, A and B, are moulded in the sequence A-B-A with no delay at the change over. The distribution of A and B at the part surface is discussed. It is shown that part deformation is dependent upon material properties and process conditions, and the rigidity may be increased by the use of skin materials of high modulus. The use of high injection and packing pressures reduces residual stresses and shrinkage, and warpage may be reduced by achieving a more uniform cavity pressure distribution. 6 refs. TAIWAN

Accession no.822899 Item 50 Antec 2001.Conference proceedings. Dallas, Texas, 6th-10th May, 2001, paper 134 THE DEVELOPING BEHAVIOR OF CORE MATERIAL AND BREAK THROUGH PHENOMENON IN SANDWICH INJECTION MOLDING Watanabe D; Hamada H; Tomari K Kyoto,Institute of Technology; Osaka,Municipal Technical Research Institute

42

(SPE) The influence of polymer viscosity ratio and the melt temperatures of the skin and core polymers on the penetration of the core material through the skin material during co-injection moulding was investigated using a spiral float mould which had a variable cavity thickness. Polycarbonates of three different viscosities and a polycarbonate/ABS alloy were used, the core material being coloured black for flow visualisation. It was concluded that break through was dependent upon the melt strength of the freezing layer of the skin polymer at the flow front. 19 refs. JAPAN

Accession no.822883 Item 51 Industria della Gomma 44, No.8, Oct.2000, p.39-43 Italian MATERIALS IN COMBINATION: THE VIEWPOINT OF THE MAIN GROUP Trends in the use of combinations of different polymers in the manufacture of footwear are discussed, and developments by the Main Group of Italy in injection moulding processes and machines for such applications are examined. MAIN GROUP EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.821965 Item 52 Plast’ 21 No.98, Dec.2000, p.33 Spanish MANNESMANN DEMATIC HITS THE TARGET A review is made of developments by Demag Ergotech in machinery for multi-component injection moulding which were featured during open days held in Barcelona by Mannesmann Dematic on 17th and 18th November 2000, with particular reference to the Ergotech 50/355120H-80V press. Mention is also made of the Company’s Max Series of large injection presses (over 2,000 tonnes clamp force) and Elexis E all-electric injection moulding machine. MANNESMANN DEMATIC SYSTEMS; DEMAG ERGOTECH; GRAM TECHNOLOGY DENMARK; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; SCANDINAVIA; SPAIN; WESTERN EUROPE

Accession no.821715 Item 53 TPE 2000. Conference Proceedings Amsterdam, Netherlands, 6-7 March 2000. Amsterdam, Netherlands, 6-7 March 2000, Paper 17

© Copyright 2002 Rapra Technology Limited

References and Abstracts

SPECIAL TECHNOLOGIES FOR INJECTION MOULDING OF TPES Pokorny P Engel Maschinenbau GmbH (Rapra Technology Ltd.; European Plastics News) Special technologies for injection moulding of thermoplastic elastomers are discussed, including multicomponent injection moulding, co-injection, back moulding of films or textiles, and foaming of thermoplastic elastomers with the MuCell (microcellular foaming) process. 1 ref. AUSTRIA; EUROPEAN UNION; WESTERN EUROPE

Accession no.820664 Item 54 Injection Molding 9, No.6, June 2001, p.41/4 DESIGNING OVERMOULDED PARTS? TIME TO CONSIDER THE TOOL Maniscalco M A list of dos and don’ts to help in the design of moulds for the manufacture of soft-touch thermoplastic elastomer overmoulded products is presented. Included are runner configuration suggestions for two-shot moulds as well as guidelines on runner cross-sectional areas. USA

Accession no.820379 Item 55 Revue Generale des Caoutchoucs et Plastiques 77, No.790, Nov.2000, p.68-9 French ENGEL: THE PLASTICS TRUMP CARD Delannoy G An account is given of developments by Engel in injection presses, including vertical and horizontal machines for rubber moulding, special machines for the processing of silicone rubbers, and machines for use in multi-material moulding. ENGEL; ENGEL FRANCE AUSTRIA; EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; WESTERN EUROPE

Accession no.818407 Item 56 Plastics Technology 47, No.2, Feb.2001, p.47/9 SEQUENTIAL GATING AND GAS ASSIST TEAM UP FOR THE FIRST TIME Knights M This article tells the story of how, for the first time ever, it is thought, two fast-growing injection moulding techniques - valve gating sequencing and gas-assist technology - have come together in one application: a 3.5lb ABS/PC computer panel, studded with bosses and

© Copyright 2002 Rapra Technology Limited

ribs, which had to be perfectly flat and show no sinkmarks or flow lines. L.B.MOLDS INC.; TOSHIBA MACHINE CO.; HEWLETT-PACKARD CO.; CAROPRESO ASSOCIATES; APW ENCLOSURE SYSTEMS; INCOE CORP.; GAIN TECHNOLOGIES; GE PLASTICS USA

Accession no.818368 Item 57 Plastics and Rubber Weekly 15th June 2001, p.7 ENGEL UK REPORTS ORDER BOOST IN TOUGH MARKET Edwards N Engel UK says it has had a considerable number of machine sales in the medium and large tonnage range this year. One 1,000-tonne and one 2,500-tonne machine have been sold to automotive supplier Sommer Allibert. In May, there were two separate deals for five medium-sized machines, of which one order was for multi-shot capability. In June, Engel received its latest order, for a 1,300-tonne machine. The company says the prospects for the machinery market were looking up, particularly in the automotive sector. ENGEL UK LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.816728 Item 58 Injection Molding 9, No.4, April 2001, p.41-2 CRITICAL NATURE OF FILL Chitwood A Joe Hoepfl of Snap-on Tools claims to have learned a valuable lesson in the use of mouldfilling analysis software that he will not forget. As a principal engineer for the company, Hoepfl designs hand tools such as screwdrivers, Pliers and wrenches. About three years ago, it implemented a program to include soft-touch handles on a number of its products, including a line of screwdrivers called Soft Grip. The screwdriver handles were to be made by overmoulding an elastomer over a PP substrate. He enlisted the aid of Santoprene TPE manufacturer Advanced Elastomer Systems. Details are given. SNAP-ON-TOOLS; ADVANCED ELASTOMER SYSTEMS LP; Accession no.815854 Item 59 Injection Molding 9, No.3, March 2001, p.52 OVERMOULDING WINNER MERGES DESIGN AND PROCESS

43

References and Abstracts

Maniscalco M The factors driving the success of a consumer product are discussed. Using Kodak’s high-profile Max Sport camera as an example, these might range from function and aesthetic appeal to price and ease of use. Behind these achievements, however, lies another explanation for the ubiquitous camera’s success; namely, it exemplifies a product designed in concert with processing needs. Now in its fourth year of production, the Max Sport relies on a patented, two-part housing overmoulded with TPE on a 220 metric-ton, two-shot press at Eastman Kodak’s Precision Plastics Molding facility in Rochester, NY. The housing consists of a clear PS substrate and a specialised compound based on Kraton G, a SEBS elastomer. To marry design requirements with processing realities, Kodak worked closely with its tooling and materials suppliers. Details are given. GLS CORP.; KRATON POLYMERS Accession no.815845 Item 60 Naefels, 2000, pp.8. 29 cms. 10/4/01 SYNERGY 2C, PLAYING WITH COLOURS AND COMPONENTS. A SUCCESS STRATEGY. SYNERGY 2C: MULTI-COMPONENT INJECTION MOULDING TO PERFECTION Netstal-Maschinen AG Features and capabilities are described for the SynErgy 2C injection moulding machine from Netstal for multicomponent injection moulding applications. The SynErgy 2C has clamping forces from 600-4200 kN and a wide selection of injection units which can be effectively combined to offer a wide scope. It can be used for all processes, including overmoulding, bi-injection and coinjection. SWITZERLAND; WESTERN EUROPE

Accession no.815385 Item 61 Kunststoffe Plast Europe 91, No.4, April 2001, p.32-3 SILICONE BONDS Kraibuhler H Arburg GmbH New injection moulding concepts are discussed which have been instrumental in the increase in the use of injection moulded silicone parts for technical applications. Such developments include multicomponent applications, sprueless injection moulding, and economic micromoulding thanks to new micrometering units. (Article translated from Kunststoffe 91 (2001) 4, pp.88-89). EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.815269

44

Item 62 Rubber and Plastics News 2 22, No.13, 9th April 2001, p.3 WACKER-CHEMIE ADDS TO LIQUID SILICONES Begin S Wacker-Chemie has expanded its line of cost-saving, selfadhesive liquid silicone rubbers. Last year the company finalised development of nine additional grades of Elastosil LR for the automotive industry. The grades differ according to their resistance to temperature, oil and coolant. Elastosil LR is said to be ideal for overmoulding thermoplastics and metal parts, in applications ranging from exhaust pipe hangers and engine mounts to multifunctional steering wheel switches, air regulator membranes and automotive cables. Elastosil LR grades incorporate an adhesion agent which slowly diffuses out of the rubber and then sticks between it and the plastic or metal during two-component injection moulding. Metal and plastic substrates can remain unprimed, saving cost and time. WACKER-CHEMIE GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.814724 Item 63 Rubber and Plastics News 30, No.17, 19th March 2001, p.9 ROLCO’S BUSINESS GROWS WITH INCREASED TPE USE Meyer B For Rolco, the moulding of thermoplastic elastomer products is beginning to rival its traditional thermoplastic business in volume. Currently, the injection moulder does about 60% of its 7-8m US dollars in annual sales in traditional plastics, with the remainder in a variety of TPEs. A year from now, that will be reversed. Rolco’s manufacturing niche is multi-shot moulding. Another plus is Rolco’s ability to combine two materials in one product that can interlock. One such product is used in firewalls. It includes two elastomers, one harder and one flexible, that goes into a firewall and allows a cable to pass from inside to outside. ROLCO INC. USA

Accession no.814588 Item 64 Kunststoffe Plast Europe 91, No.3, March 2001, p.41-4 BONDING STRENGTH OF THERMOPLASTIC COMPOSITES Kuhmann K Hengst Filterwerke GmbH The multi-component injection moulding of thermoplastic composites - a process which is gaining increasing ground - combines different plastics into a composite injection

© Copyright 2002 Rapra Technology Limited

References and Abstracts

moulded part with integrated functions. At the same time, since elaborate assembly, handling and pre-treatment steps can be dispensed with, it is possible to achieve new component structures with a high rationalisation potential. Aspects covered include different material combinations, moulded part design/part layout, the injection moulding process, and assessment and need for action. (Translated from Kunstoffe 91, 3, 2001, p.115-18). EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.812956 Item 65 Kunststoffe Plast Europe 91, No.3, March 2001, p.39-41 English; German INGENIOUSLY COMBINED - PROFITABLY MANUFACTURED MULTI-COMPONENT INJECTION MOULDING OF THERMOPLASTICS AND THERMOSETS Hunold D; Hoster B; Schumacher B Krauss-Maffei Kunststofftechnik GmbH; Iserlohn,Markische Fachhochschule New processing methods are reported to be making it possible to produce combinations of plastics with extremely different property profiles in a cost-efficient manner. The injection moulding of thermoplastic/ thermoset combinations in a single production process, involving just a few process steps, is opening up the way to new products. Aspects covered include thermoset plastic parts with elastic functions, material combinations with dissimilar adhesion, polymer injection up to a defined line, thermoplastic shortening cycle times and the combination of materials to facilitate assembly. (Translated from Kunstoffe 91, 3, 2001, p.108-110). EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.812955 Item 66 Kunststoffe Plast Europe 91, No.3, March 2001, p.32-4 English; German HOT-AND COLD SOLUTION Keusgen H Braun Formenbau GmbH Composites of thermoplastic polymer and liquid silicone rubber LSR are of interest due to the wide variety of applications in which they can be used. Trouble-free processing of these totally disparate materials in one mould requires that the cavities of the semi-finished part be thermally insulated from those of the finished moulded part. Braun Formenbau has devised a method of coinjection, offering an alternative to the transfer process. Aspects covered include thermal isolation of the cavities, mechanical locking of the components, an integrated rotary device, control of mould temperature, two different

© Copyright 2002 Rapra Technology Limited

gating systems, demoulding and slide bar control. (Translated from Kunstoffe 91, 3, 2001, p.92-4). EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.812952 Item 67 Meinerzhagen, 2000, pp.16. 29 cms. 18/4/00 LIM - LIQUID INJECTION MOLDING Battenfeld GmbH The injection moulding of liquid silicone rubber is discussed with reference to Battenfeld GmbH’s machines. The properties of liquid silicone rubber are examined, and its processing considerations are described. The injection unit is a modular construction which can accommodate various shot volumes. It contains the following components: plasticiser screw with LSR optimised geometry for metering and mixing of fed-in components as well as reproducible injection of LSR in the heated mould; back flow prevention for repeatable shot volumes, specially adapted to LSR properties; screw sealing for the prevention of material loss due to the low viscosity of LSR; a liquid cooled nozzle for the prevention of curing; pneumatically activated needle shut-off nozzle; and connections for 2 component mixing and dosing units. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.812504 Item 68 Kunststoffe Plast Europe 91, No.2, Feb.2001, p.20-2 English; German PEEL TESTING OF MULTI-COMPONENT MOULDINGS. QUANTITATIVE DETERMINATION OF THE BOND STRENGTH OF HARD/SOFT COMBINATIONS Aumuller W Plastic Technology Service Until recently, there has been no practical method for quantitatively measuring the bond strength of hard/soft combinations of thermoplastic elastomers and engineering thermoplastics. Now, with newly developed test specimen geometry and the use of a test method that can determine peel strength, it is possible to measure and compare bond strengths. Previous test methods are outlined, together with a peel test from Plastic Technologie Service in which the soft component is pulled away from the hard component. 5 refs. (Translated from Kunstoffe 91, 2001, 2, p.46/50). EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.809449 Item 69 Plastics News International Jan./Feb.2001, p.8

45

References and Abstracts

VERSATILE NOZZLE SYSTEM FOR MULTIMATERIAL PROCESSING Battenfeld has developed a modular nozzle system based on inserts which allows injection moulding processors to benefit from the entire range of multi-polymer technology. The standard system with a nozzle opening for multi-layer injection moulding can be easily changed over for interval injection moulding, classic two-component techniques with two nozzle openings or single-component processes. The multitude of multi-polymer techniques can be categorised into mould-related processes and machine related processes. The former consist of injecting two or more polymers into the mould via two separate nozzles. The mould-related method involves the use of moulds with rotary pistons. These seal the cavity during the injection of the first polymer, and allow the cavity to open when the second component is injected. Another possible approach is the use of moulds with several cavities, whereby the preform is taken from the cavity and placed into another where it is encapsulated by another layer of injection moulded polymer. The replacement process can either be carried out by a handling device, a rotary disk or by a rotary index disk inside the mould. Details are given. BATTENFELD AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.809382 Item 70 SPE Automotive TPO Global Conference 2000. Conference proceedings. Dearborn, Mi., 2nd-4th Oct.2000, p.275-9 COINJECTION MOULDED TPO FASCIA PRODUCTION Smith M; Valentage R Nascote Industries; Solvay Engineered Polymers (SPE,Detroit Section) The automakers and systems integrators need reduced costs, increased efficiencies and potential recyclability in TPO bumper/fascias. Full production in materials, design, tooling and equipment are now being optimised for TPO fascias using the coinjection moulding process. Advantages of the process and comparisons to standard injection moulding are addressed. USA

Accession no.807834 Item 71 SPE Automotive TPO Global Conference 2000. Conference proceedings. Dearborn, Mi., 2nd-4th Oct.2000, p.255-8 ADVANCED MOULDING PROCESSES FOR TPOS IN THE AUTOMOTIVE INDUSTRY Ehritt J Battenfeld of America Inc.

46

(SPE,Detroit Section) The automotive TPO industry is under significant pressure to consolidate parts, eliminate paint, reduce costs and recycle. Advanced processes such as coinjection moulding, two-shot moulding, gas assist and Mucell are emerging as logical approaches to meeting these needs. A wide variety of applications of these processes is introduced along with specific applicability for automotive TPOs. USA

Accession no.807831 Item 72 Kunststoffe Plast Europe 91, No.1, Jan.2001, p.22-4 SHORT-TERM SHRINKAGE IN MULTICOMPONENT INJECTION MOULDING Karlinger P; Buerkle E A method developed at Rosenheim Technical College in combination with Krauss-Maffei Kunststofftechnik for the measurement of the characteristic values of shrinkage in the design of multi-component injection moulds is presented. An investigation of the effects of processing parameters on the short-term shrinkage behaviour and mould shrinkage of PP revealed that cooling time and holding pressure level had the most influence on shrinkage behaviour. (Kunststoffe, 91, No.1, 2001, p.54-9) ROSENHEIM,FACHHOCHSCHULE; KRAUSSMAFFEI KUNSTSTOFFTECHNIK EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.806694 Item 73 World Plastics Technology 2000, p.85 FOLLOW THE LEADER Multi-shot moulding techniques are described with reference to preferred methods and mould design. The most versatile and widely used method involves mould rotation within a horizontal machine. The method is said to support a wide variety of colours and/or materials, and provides for fast shot-to-shot sequencing for materials bonding. The design of the mould rotating devices used in this technique is examined, and the ability of Caco Pacific to provide mouldings, hot runner systems, mould rotating plates and complete moulding systems, including machines and robotics is reported. CACO PACIFIC USA

Accession no.806032 Item 74 Lossburg, 1999, pp.32. 29 cms. 21/2/01 SPECIAL APPLICATIONS IN INJECTION

© Copyright 2002 Rapra Technology Limited

References and Abstracts

MOULDING TECHNOLOGY: TOTAL UTILISATION OF INNOVATIVE ENGINEERING. TECHNICAL INFORMATION Arburg GmbH & Co. Special applications for which the Arburg range of injection moulding machines are suitable, are described, with reference to machines capabilities and models. In particular, the injection moulding is described of multicomponents, the use of interval injection moulding for special effects, sandwich injection moulding, composite injection moulding, marbling injection moulding techniques, the processing of liquid silicone rubbers, thermoset processing, elastomer processing, gas injection moulding technology, powder injection moulding, machines for insert-loaded parts, injection moulding of optical discs, production of PETP preforms, and smart card production. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.804329

TWO MATERIALS AND CO-INJECTION TECHNOLOGIES This article points the spotlight at “Stratos Bx” coinjection moulding machines, manufactured by OiMA SpA of Italy. Full details are provided of the machines and their applications, and a company profile of OiMA is also presented. OIMA SPA EUROPE-GENERAL; EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.802422 Item 78 Polymer Recycling 5, No.2, 2000, p.63-70 RECYCLING OF AUTOMOTIVE SHREDDER RESIDUE BY COINJECTION MOULDING Cain R L; Goodship V; Love J C; Smith G F; Tucker N Warwick,University

Developments in two-material, multi-material, two-colour and multi-colour injection moulding are examined, and a survey is made of machinery manufactured by a number of companies for use in these processes.

Automotive shredder residue (ASR) is the remains of an end-of-life vehicle once the dismantlers have reclaimed all the valuable parts and metals for recycling. After size reduction, to reduce bulk volume, the final waste stream is usually landfilled. A novel method whereby this mixed material waste stream may be reused in the coinjection moulding process is described. The ASR is used as a moulding core material and is encapsulated in a virgin plastic skin. This work resulted in a patent. The paper describes this initial work with reference to processing technique, mechanical properties and an assessment of the recyclability of ASR mouldings. 15 refs.

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; ITALY; SWITZERLAND; WESTERN EUROPE

EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.803906

Accession no.801919

Item 76 Italian Technology No.3, 2nd Oct.2000, p.34-6 ROTARY MACHINES FOR STRUCTURAL FOAM MOULDING AND CO-INJECTION

Item 79 Plastics News(USA) 12, No.40, 4th Dec.2000, p.9 PLASTICS SEEKING TO USURP THE UNDERWIRE Higgs R

Item 75 Macplas 25, No.218, May 2000, p.43/57 Italian MULTIPLE INJECTION MOULDING Cairati C Assocomaplast

This article focuses in detail on injection moulding machines with multi-station rotary closing systems, manufactured by Presma SpA of Italy. A company profile of the company, which was founded in 1937, is also included. PRESMA SPA; SIEMAG; OMR ENGINEERING AFRICA; CANADA; CHINA; EASTERN EUROPE; EGYPT; EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; GERMANY; INDIA; ITALY; JAPAN; LATIN AMERICA; RUSSIA; UK; USA; WESTERN EUROPE; WORLD; YUGOSLAVIA

Accession no.802424 Item 77 Italian Technology No.3, 2nd Oct.2000, p.24-5

© Copyright 2002 Rapra Technology Limited

After two years of careful R&D, including tests on more than 50 plastic materials, the origination of prototype tooling, six months of moulding trials, with wearer tests resulting in continual shape refinement, the Bioform bra was finally born. The bra is based on a multimaterial, injection moulded piece consisting of a glass-reinforced PP component to provide breast support, with a softer body-forming thermoplastic elastomer cup. Two customer moulders, Denroy Plastics and SMP Multi-Shot, are supplying the two-shot piece. CHARNOS LINGERIE EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.801792

47

References and Abstracts

Item 80 Revista de Plasticos Modernos 79, No.525, March 2000, p.220/2 Spanish CAR PRODUCTION, A MARKET OF INCREASING IMPORTANCE TO THE PLASTICS INDUSTRY Netstal Maquinas SA Applications of plastics in the manufacture of cars are discussed with particular reference to injection moulded multi-component and multi-colour parts. Brief mention is made of Netstal’s SynErgy 2C injection moulding machines and their use in the production of such components. NETSTAL MASCHINEN AG EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN; SWITZERLAND; WESTERN EUROPE

Accession no.800836 Item 81 European Rubber Journal 182, No.12, Dec.2000, p.22-3 INJECTION MOULDERS EXPLORE COINJECTION Shaw D Although moulders have been using metal inserts for rubber-to-metal components for many years, the latest trend is for rubber-to-plastic bonding, injecting plastic and rubber into the same mould cavity. Full details of this approach are given with the help of looking at Schneegans GmbH of Germany, a company specialising in coinjection moulding. SCHNEEGANS; HUELS AG AUSTRIA; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.798736 Item 82 Racine, Wi., c. 2000, pp.2. 27 cms. 14/12/00 ENGINEERED SOLUTIONS Flexfab Molded Products LLC Custom moulding services from Flexfab Molded Products are described. The company specialises in the design and manufacture of switch, keymat and keypad assemblies and components moulded in silicone rubber. Brief details are given of the company’s expertise in bonding, insert and overmoulding of metals and plastics with liquid silicone rubber, and its proprietary finishing techniques, which include wear resistant printing and painting, laser etching, legend protection coating and capping, as well as press-fit and bonded plastic keys. In particular, Flexfab Molded Products are used in the automotive industry. USA

Accession no.797591

48

Item 83 Plastics and Rubber Weekly 1st Dec.2000, p.10-1 ONE FOR THE LADIES Smith C At the heart of the Bioform bra design is a two-component plastic moulded support structure comprising a rigid plastic armature, which takes the place of the underwire in a traditional bra, overmoulded in soft flexible TPE to make it more comfortable for the wearer. The problem for designer PDD was there was no specific data on which to build on. On the structural side, there was only the shape of a steel wire from an existing bra to work from. SMP Multi-Shot made one mid-range pair of prototype tools. Highly isotactic PP from Solvay was selected for the rigid core and a specially formulated TPE from Kraiburg for the flexible component. Initial sales levels of the Bioform bra, which went on sale in October, have been good. PDD EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.797041 Item 84 Injection Moulding Asia 3, No.10, June/July 2000, p.13 MULTIPLE SOLUTIONS FROM K-M This article highlights the latest technology from KraussMaffei Plastics Machinery, the German injection moulding machine manufacturer. Information is presented on the company’s complete range of machines for multicolour and multi-component injection moulding. KRAUSS-MAFFEI KUNSTSTOFFTECHNIK EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.795814 Item 85 Modern Plastics International 30, No.10, Oct.2000, p.24-5 THERMOPLASTIC/THERMOSET COPROCESSING SHOWS PROMISE Mapleston P This article discusses thermoplastic/thermoset coprocessing, and looks at co-moulding thermoplastics and thermosets by over-moulding or coinjection moulding. The process of coextruding thermoplastic vulcanisates and EPDM is also discussed. RAPRA TECHNOLOGY LTD.; DSM ELASTOMERS; KRUPP ELASTOMERTECHNIK; KRAUSSMAFFEI; BIP; PERSTORP COMPOUNDS; ADVANCED ELASTOMER SYSTEMS; TROESTER; METEOR GUMMIWERKE BELGIUM; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; NETHERLANDS; SCANDINAVIA; SWEDEN; UK; WESTERN EUROPE

Accession no.795335

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Item 86 European Plastics News 27, No.10, Nov.2000, p.25 STACK MOULD BOOSTS PHONE PRODUCTION A horizontally-revolving revolving stack mould has been developed by Ferromatik Milacron and mould-maker Foboha, which the companies claim almost trebles the output of multi-component parts. The system is described fully in this article. GRAM TECHNOLOGY; WILDEN MOULDMAKING & AUTOMATION ENGINEERING; FOBOHA; FERROMATIK MILACRON; SIEMENS DENMARK; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; SCANDINAVIA; WESTERN EUROPE

Accession no.795288 Item 87 European Plastics News 27, No.11, Nov.2000, p.49 FEATHER IN THE CAP Vink D As PETP increasingly replaces glass for mineral water, carbonated soft drinks and beer, it is mainly plastic screw caps rather than metal crown closures that are being used to seal the bottles. An alternative to caps with separate sealing lips is a true two-component cap, combining a base polymer such as PE or PP, with a moulded-in elastomeric seal. Gefit has developed a mould with up to 64 cavities, which has sliding inserts instead of traditional rotating stack moulds. The new mould is said to be capable of achieving cycle time of less than 7.5 seconds for a 28mm diameter, two-component cap on Netstal Synergy machines. KTW says it can make a single component cap design, weighing 2.8g and with an integrated tamper band, in a cycle time of approximately 6 seconds in HDPE and 9 seconds in PP. NETSTAL; GEFIT; KTW; GRAM TECHNOLOGY WESTERN EUROPE

Accession no.795157 Item 88 Plastiques Flash No.315, Dec.1999/Jan.2000, p.86-8 French ON COURSE FOR LARGE PRESSES Developments by Demag Ergotech in large injection presses and electrically driven presses are reviewed. Machinery developed by the Company for gas-assisted, two-material and multi-material injection moulding is also described. DEMAG ERGOTECH; MAXIMATOR; GRAM TECHNOLOGY DENMARK; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; SCANDINAVIA; WESTERN EUROPE

Accession no.795039

© Copyright 2002 Rapra Technology Limited

Item 89 158th. ACS Rubber Division Meeting - Fall 2000. Conference preprints. Cincinnati, Oh., 17th.-19th. Oct. 2000, paper 63 NEW TPE BONDING TECHNOLOGY AND VARIOUS OVERMOLDING PROCESSES COMBINE FOR CREATIVE, COST-EFFECTIVE TPV APPLICATIONS Tan O H C; Mehta S Advanced Elastomer Systems LP (ACS,Rubber Div.) This paper outlines advances in the development and use of new alloys which allow thermoplastic vulcanisates (TPVs) to heat-fuse with numerous substrates including ABS, nylon, polycarbonate, PC/ABS, ASA, PS and PMMA in addition to polyolefinic substrates. Additional information is provided on key TPV processing characteristics which accommodate these new bonding characteristics in insert moulding, two-shot-plus moulding, co-injection moulding and coextrusion, to further expand the creative and cost-effective use of TPVs. 6 refs. USA

Accession no.794167 Item 90 158th. ACS Rubber Division Meeting - Fall 2000. Conference preprints. Cincinnati, Oh., 17th.-19th. Oct. 2000, paper 42 BONDING OF THERMOPLASTIC ELASTOMERS TO PLASTICS DURING MULTICOMPONENT INJECTION MOLDING PROCESSES Mehta M; Verma G; Barry C M F; Stacer R G Massachusetts,University (ACS,Rubber Div.) Results are discussed of an experimental investigation which was carried out to study the development of bond strength between thermoplastic elastomers and conventional thermoplastics during multi-component injection moulding. Representatives from each of the major classes of thermoplastic elastomers were moulded against a range of polar and non-polar thermoplastics using either two-shot or insert injection moulding techniques. Interfacial morphology was characterised through part dissection and compared with contact angles measured at the bonding temperature, as well as other surface properties. Resultant bond strengths were determined using either butt joint or double-lap shear test specimen geometries, and a specific application is considered in which an oil-resistant thermoplastic urethane rubber is bonded to a polycarbonate support ring, in order to evaluate the role of a full range of processing conditions on the resultant bond strength. 15 refs. USA

Accession no.794148

49

References and Abstracts

Item 91 Patent Number: US 6099780 A1 20000808 METHOD OF THREE LAYER INJECTION MOLDING WITH SEQUENTIAL AND SIMULTANEOUS COINJECTION Gellert J U A method of multi-cavity valve gated three layer injection moulding to form containers or preforms having a middle layer of a barrier material between inner and outer layers of a PETP type material. The barrier material is injected through an annular channel in each heated nozzle simultaneously with the PETP type material being injected through a central melt bore in each valve pin. This reduces cycle time and produces a thicker inner layer of PETP. CANADA; USA

Accession no.793864 Item 92 Antec 2000.Conference proceedings. Orlando, Fl., 7th-11th May, 2000, paper 94 POLYMER MELT FLOW BEHAVIOR IN THE COINJECTION MOLDING PROCESS Nguyen K T; Turcott E; Derdouri A; Ait Messaoud D; Sanschagrin B; Salamon B A; Koppi K A Canada,National Research Council; Quebec,Ecole Polytechnique; Dow Chemical (SPE) Co-injection moulding was studied using skin/core combinations of: polycarbonate (PC)/ABS, high melt index polycarbonate (HMI PC)/PC and PC/HMI PC. Flow visualisation was obtained by adding pigment to the core material. The mould was a central-gated rectangular cavity of variable thickness in the range 1-7 mm. A more stable interface was achieved when the skin material had the lower viscosity, and fingering was observed when the viscosity of the core material was much lower than that of the skin. 9 refs. CANADA; USA

Accession no.793825 Item 93 Antec 2000.Conference proceedings. Orlando, Fl., 7th-11th May, 2000, paper 93 MULTI-COMPONENT INJECTION MOLDING PART I: INTERFACE AND MICROSTRUCTURE DEVELOPMENT Palluch K P; Isayev A I Akron,University (SPE) Software was developed to simulate the interface and microstructure development during multicomponent coinjection moulding. A finite element method was used to calculate the transient non-isothermal flow and to predict the stress-induced crystallisation occurring in semicrystalline polymers. The model was applied to the

50

injection of high molecular weight polypropylene (PP) as the skin material and low molecular weight PP as the core material, where stress-induced crystallisation occurred in the skin material. In a second trial, the low molecular weight PP was used as the skin material, and exhibited shear-induced crystallisation of up to 23% of the mould half-thickness. In the third trial, low molecular weight PP was used as the skin material and high molecular weight polystyrene as the core. In this case no shear-induced crystallisation was observed in the PP because it had the higher critical shear rate, and the maximum shear rate was located at the interface. 6 refs. USA

Accession no.793824 Item 94 High Performance Elastomers 2000. Conference proceedings. Berlin, Germany, 10th-11th Oct.2000, paper 8 TWO-SHOT INJECTION MOULDING HIGH PERFORMANCE AND CONVENTIONAL ELASTOMERS Arning M Engel Vertriebsgesellschaft mbH (Rapra Technology Ltd.; European Rubber Journal) Due to the cost of high performance elastomers there is much interest in reducing the amount of these materials in moulded rubber products without any compromises as far as the quality of the products is concerned. Attempts are made to combine high performance elastomers resulting in a lower cost material. The machine and mould technology available for multi-component products is described. This involves the classic two-component moulding process using a two-shot machine and the comoulding process where an elastomeric material is completely covered by a second material. The manufacturing methods are discussed regardless whether or not high performance elastomers are involved. Some of these moulding techniques are already used in combination with high performance elastomers. AUSTRIA; EUROPEAN UNION; WESTERN EUROPE

Accession no.792370 Item 95 Kunststoffe Plast Europe 90, No.10, Oct.2000, p.28-30 TRIPLE COMBINATION Herbst R; Johannaber F Elexis Unternehmensgruppe; Bayer AG A review is given of machine developments for multicomponent injection moulding of thermoplastics, elastomers and thermosets. The latest technology described uses stack moulds and handling units for increasing profitability through high output rates from relatively small machines. Gripping and handling systems, combined with magazining facilities and a variety of intermediary processing methods are demonstrated to

© Copyright 2002 Rapra Technology Limited

References and Abstracts

expand the field of application for multi-component injection moulding. 1 ref. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.791852 Item 96 Kunststoffe Plast Europe 90, No.10, Oct.2000, p.22-4 SUCCESSFULLY INTRODUCING NEW INJECTION MOULDING TECHNOLOGIES Michaeli W; Franz A IKV The need to stay ahead of developments in the competitive field of injection moulding by use of specialised injection moulding techniques is acknowledged. The introduction of new technology within a company is considered with reference to four steps: the search phase in which information is collected; the selection phase whereby decisions are taken by project teams; the implementation phase, and the utilisation phase which involves continuous improvements. The use of such a structured approach claims to reduce potential bottlenecks and problems associated with the introduction of new technology. 6 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.791850 Item 97 Kunststoffe Plast Europe 90, No.10, Oct.2000, p.16-9 TRENDS IN INJECTION MOULDING Johannaber F; Thoma H Bayer AG; Ferromatik Milacron Maschinenbau GmbH A review is presented of injection moulding machine technologies and special processes. Market trends are discussed such as the choice of machines with or without tiebars, the choice of two or three platen machines, the design of the injection unit and screws, and decisions relating to hydromechanical drives, fully electric machines or complementary electrical drives, and hybrid machines. Special processes considered include multicomponent injection moulding, moulding of thermosets including silicone rubber, direct gas injection, gas and water assist technologies, external gas moulding, the moulding of hybrid structures, and micromoulding. 1 ref. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.791848 Item 98 Plastics and Rubber Weekly 13th Oct.2000, p.30 TURNING A PROFIT Smith C Wilden Group has put a new two-component moulding technology for mobile phone casings into production that

© Copyright 2002 Rapra Technology Limited

it believes will provide cost savings of up to 25% compared with existing manufacturing systems. The technology is based on a hot runner-fed rotating stack mould concept from Foboha and a two-component moulding machine manufactured by Ferromatik Milacron. The Siemens phone casing is being produced in two coloured grades of Cycoloy PC/ABS from GE Plastics. Foboha says its 4+4 cavity rotary stack system allows a production rate of 960 parts per hour to be achieved from a 100-tonne moulding machine. WILDEN GMBH & CO.KG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.791092 Item 99 British Plastics and Rubber Oct.2000, p.36-7 FERROMATIK MILACRON TAKES A MORE AGGRESSIVE STANCE ON MOULDING MACHINE MANUFACTURE Ferromatik Milacron has outlined the future for its European injection moulding machine production and is putting a lot of faith in all-electric machines. The company is aiming to increase machine production at Malterdingen in Germany by 10% per year, starting from a target of 800 machines this year. It is introducing the Maxima range of two-platen machines which, at the lower tonnage sizes, will be aimed at the standard machine market, and will be extended upwards to 3,100 tonnes. Alongside these machines, the company continues with its K-TEC series of fully hydraulic three-platen machines, Mono-sandwich and other speciality machines. FERROMATIK MILACRON GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.791037 Item 100 Patent Number: US 6062840 A1 20000516 HOT RUNNER SYSTEM FOR COINJECTION MOLDING Lee C W; Moss M D Dynisco Hotrunners Inc. A coinjection molding system for injecting skin and core material into a mould cavity includes a three position actuator for moving a valve pin into a closed position in which neither skin nor core flow is permitted, a middle position in which only skin flow is permitted and an open position in which skin and core flow is permitted. The actuator includes a first piston slidably mounted in an actuator housing and a second piston, attached to the valve pin, slidably mounted within the first piston. A shut-off is provided in the manifold for preventing skin flow to a particular nozzle during sequential gating. USA

Accession no.790500

51

References and Abstracts

Item 101 Injection Molding 8, No.9, Suppl. Sept.2000, p.18/44 MOLDING MACHINE TRENDS

replacement for glass, which until now, has been difficult to substitute with a scratch resistant and optically clear plastic. WARWICK,UNIVERSITY

A review is presented of injection moulding machines exhibited at the recent NPE exhibition. Machine designs and innovations are described and include new toggle presses, twin-platen presses, all-electric machines, hybrid machines, vertical clamp insert moulding presses, automated insert moulding machines, and speciality machines for metal and ceramic powder moulding, inmould decoration, micromoulding machines, minimoulding machines, Mucell microcellular moulding technology, multi-moulding machines, PETP preform machines, machines for thin-wall containers, and machines for thermoset injection moulding. Accession no.790270

EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Item 102 Polymer Process Engineering ’99. Conference proceedings. London, June 1999, p.109-116 ANALYSIS OF CAVITY FILLING PHENOMENA USING ROTARY RUNNER EXCHANGER SYSTEM Yokoi H; Kanetoh Y; Murata Y Tokyo,University; Ube Industries Ltd. Edited by: Coates P D (Institute of Materials; UK,Interdisciplinary Research Centre in Polymer Science & Technology; Bradford,University) Dynamic visualisation already plays a very important role in the field of understanding in-mould phenomena of the injection moulding process. In order to extend the possibility visualisation to more sophisticated analysis, a new colour-marking system is developed for melt passing through the gate, based on the rotary runner exchanger and co-injection moulding technology. Application of this technology to sandwich moulding is also very promising in terms of obtaining a high occupation ratio of the core material by quick material change at gate. 4 refs. JAPAN

Accession no.790085 Item 103 Automotive Engineer 25, No.9, Oct.2000, p.19 CLEAR BENEFITS FOR PLASTIC WINDSCREEN A dual injection moulding technique is being used by researchers at the Warwick Manufacturing Group of the University of Warwick, to produce car windscreens to replace glass versions. The process creates a window with a light impact resistant polycarbonate core surrounded by a tougher plastic skin which is more scratch resistant and weather proof. The material could be used as a

52

Accession no.789657 Item 104 European Plastics News 27, No.9, Oct.2000, p.49 ELECTRIFYING PRODUCTIVITY Vink D A typical Braun electric toothbrush is still made of 20-30 parts, despite productivity benefits through increasing use of multi-component moulding techniques, mainly for hard-soft PP/TPE combinations. The company is currently moving towards using an increasing number of all-electric injection moulding machines to achieve its moulding requirements. The aim is to increase the proportion of all-electric machines from today’s 32% to 55%. For the future, Braun seeks remote diagnosis to supplement its current remote monitoring, self optimising moulding machines, improvements in process stability, simpler operation and reduced wear. BRAUN AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.788053 Item 105 Molding Systems 58, No.1, Jan.2000, p.28-31 LOWER MATERIAL COSTS? FEWER DESIGN CONSTRAINTS? McRoskey J Co-Mack Technology Inc. This article focuses on the process known as coinjection moulding (and also as sandwich moulding). It explains the process itself, compares it to conventional injection moulding, and looks at its advantages. Next it considers specific applications, and lastly discusses future market penetration. IBM; SIEGEL-ROBERT AUTOMOTIVE & DIVERSIFIED PRODUCTS; DAIMLERCHRYSLER USA

Accession no.786592 Item 106 European Plastics News 27, No.8, Sept.2000, p.60 ENGEL - THE “ONE-STOP-SHOP” ADDRESS Engel is a full scope supplier of injection moulding machines from 20 to 5,500 tonnes clamp force and shot weight from 18 to 52,000 grams of PE, handling robots and robot

© Copyright 2002 Rapra Technology Limited

References and Abstracts

ancillaries, as well as injection moulds for small and midrange applications, with special focus on multi-material or multi-shot moulding systems. The tiebarless machine concept is now available in the clamp force range from 25 to 600 tonnes. The Engel mouldmaking profit centre offers special know-how for medical, electronic and automotive applications for multi-material or multi-colour jobs, with special focus on hard and soft material combinations. ENGEL AG AUSTRIA; EUROPEAN UNION; WESTERN EUROPE

Accession no.785246 Item 107 Plastics and Rubber Weekly No.1847, 28th July 2000, p.16 STANLEY TOOLS TEAMS UP ON MULTI-SHOT SCREWDRIVERS Bagshaw S Stanley Tools, Engel and Burnett Polymer Engineering have developed a revolutionary four-shot process to manufacture screwdriver handles. Stanley’s Dynagrip Pro range has been developed to ensure faster cycle times and higher impact resistance and torque for the finished product. The handles are manufactured using a nylon core over which is moulded two layers of PPE. A final TPE coating is then applied. STANLEY TOOLS; ENGEL AG; BURNETT POLYMER ENGINEERING EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.785149 Item 108 European Rubber Journal 182, No.9, Sept.2000, p.28/31 SILICONE GRADES FOR CO-MOULDING Shaw D Wacker-Chemie has developed a new grade of liquid silicone elastomer, Elastosil LR. The benefit of this material is that it offers easy mould release after a short period of elevated temperatures, such as the cure cycle, but then goes on to develop good bond strengths over a period of 24 hours or so. This makes it ideal for overmoulding processes or where a thin layer of silicone needs to be applied over another substrate. The material bonds to thermoplastics, although not all. Applications include water-resistant mobile phones, shower heads and electrical connectors. The company is introducing a high temperature vulcanisation grade of the self-adhesive silicone later this year which has been developed for adhesion to metals. One potential application is for exhaust pipe mounts used in cars. WACKER-CHEMIE GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.785116

© Copyright 2002 Rapra Technology Limited

Item 109 Modern Plastics International 30, No.7, July 2000, p.56-60 MULTICOMPONENT TECHNOLOGIES RESHAPE INJECTION MOLDING Mapleston P; Moore S A review is presented of developments in the injection moulding industry with reference to trends in multicomponent and multi-colour moulding technologies. Descriptions of special features of injection moulding machines are given which aim to combine functionality and aesthetics in one production step to deliver favourable economics required by key markets such as packaging and automotive industries. Trends and machine developments for co-moulding, multilayer technology, and sandwich moulding are discussed, and reference is made to machine designs exhibited at NPE 2000 and Plast 2000. WORLD

Accession no.784683 Item 110 Patent Number: US 6045733 A1 20000404 METHOD FOR MANUFACTURING A SHOE SOLE HAVING TWO DENSITIES Chu S-J; Wu J-F; Tseng C-H; Chen C-L; Chang C-P Pao Chen Corp. This includes preparing an inside part, which has two passages defined therethrough, placing the inside part into a mould, injecting foam material into the mould to let the foam material fill the two passages and heating the foam material to form a bonded combination and removing the bonded combination from the mould and drying the combination. USA

Accession no.784563 Item 111 Patent Number: US 6051295 A1 20000418 METHOD FOR INJECTION MOLDING A MULTI-LAYER PREFORM FOR USE IN BLOW MOLDING A PLASTIC BOTTLE Schloss F M; Balduff D C Coca-Cola Co. A multilayer plastic perform formed from a combination of virgin and recycled plastic such as PET so that the resultant blow-moulded bottle has a reduced tendency for bottom failure in spite of the use of recycled plastic. A first plastic preform for providing the inner layer of the multi-layer preform is provided with spaced channels on the exterior surface of a closed end thereof extending from a central region of that end to the sidewalls. An injection mould cavity is provided with a like plurality of channels formed therein in a closed end thereof communicating with the injection gate of an injection moulding apparatus. The first plastic preform is inserted into the injection mould cavity with the respective channels of the preform

53

References and Abstracts

and the injection mould cavity substantially aligned. A second layer of plastic material is overmoulded onto the first layer by injection moulding in the cavity. A third layer of plastic material may be overmoulded on the second layer to form a three-layer preform. Preferably the first and third layers are formed from virgin plastic and the second layer is formed from recycled plastic. USA

Accession no.783537 Item 112 British Plastics and Rubber July/Aug.2000, p.27 PLAN TO USE SANDWICH MOULDING FOR CAR WINDOWS Research currently being undertaken at the University of Warwick’s Warwick Manufacturing Group into automotive glazing, is briefly reviewed. The sandwich moulding process has been refined such that it can be used for optically critical components, and although, no details are disclosed, it is reported that the essence of the technique is in the control of the gating to enable a uniform thickness to be formed. The production of scratch and weatherable coated polycarbonate is referred to, but no details are given, as is the simultaneous injection process in which the polycarbonate forms a core inside a tougher plastic skin. WARWICK,UNIVERSITY EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.780449 Item 113 British Plastics and Rubber July/Aug.2000, p.21-2 THERMOSETS ADD AN EXTRA DIMENSION TO TWO COMPONENT INJECTION MOULDING Two-component injection moulding, in which a thermoplastic is injected in the same cycle as a thermoset is being investigated by Krauss-Maffei, which has build a two-component machine in association with the Technical University of Iserlohn. Experimental work into thermoplastic/thermoset two-component moulding is described, with examples of materials used and applications. KRAUSS-MAFFEI; ISERLOHN,TECHNICAL UNIVERSITY EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.780441 Item 114 Rubber World 222, No.3, June 2000, p.36/48 MULTI-COMPONENT INJECTION-MOULDING OF RIGID-FLEXIBLE COMBINATIONS

54

Ronnewinkel C; Haberstroh E Institut fur Kunststoffverarbeitung Multi-component injection moulding offers ecological and economical advantages. Combinations of rigid and flexible materials are of major interest to the industry. Due to their properties, curing rubbers and liquid silicone rubbers allow extended applications of rigid-flexible combinations and can substitute rubber-metal parts. The examinations show a good adhesion strength between thermoplastics and LSR, and between polyamide 6,12 and X-NBR rubber. In order to find suitable mould concepts for these material combinations, it will be demonstrated how to use computer simulation for the analysis of temperature distribution and curing rate. 12 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.780117 Item 115 Rubber World 222, No.3, June 2000, p.26/35 NEW TRENDS IN SILICONE ELASTOMER TECHNOLOGY Burkus F S; Amarasekera J General Electric Co.,Silicones Div. Siloxanes offer unique properties as elastomers and therefore are being used in increasing amounts for such applications. Liquid injection moulded silicone materials have excellent physical and chemical properties which make them suitable alternatives to standard millable and pourable siloxane elastomers. New advances in liquid injection moulded siloxane materials, including selfbonding, low compression set and controlled force deflection, address some previous issues that have limited the use of these systems in certain applications. Advances in mould design have enabled a two-shot ETP/liquid injection moulded elastomer system to be developed. 6 refs. USA

Accession no.780116 Item 116 Patent Number: US 6036901 A1 20000314 PROCESS FOR PRODUCING ELECTRONIC PARTS Yumoto T Sankyo Kasei KK An electronic part having a complicated internal configuration is integrally moulded without dividing the configuration into a number of sections, thereby reducing the cost and improving the quality of the electronic part. The manufacturing process comprises producing a core to be used in the subsequent injection moulding, which corresponds to the complicated internal configuration of the electronic part, by the injection moulding of a polyvinyl alcohol-based resin containing an oxyalkylene

© Copyright 2002 Rapra Technology Limited

References and Abstracts

group, producing a second stage product which has the core inserted therein and which has a ridgy projection as a circuit pattern forming area on the surface thereof by the injection moulding of a metallisation-grade aromatic polyester liquid crystalline polymer, immersing the second stage product in hot water under heating to dissolve the core away in hot water, roughening the surface of the second stage product and then providing a catalyst thereto to produce a third stage product, inserting the third stage product into a mould cavity and then injecting a nonmetallisation-grade liquid crystalline polymer into the mould cavity encircling the third stage product by injection moulding so that the surface excluding the ridgy projection as a circuit pattern forming area is coated with the liquid crystalline polymer to obtain a fourth stage product, and finally metallising the surface of the circuit pattern forming area exposed on the external peripheral surface of the fourth stage product to form an electrically conductive circuit. JAPAN; USA

Accession no.778654 Item 117 Polymer Engineering and Science 40, No.5, May 2000, p.1165-76 CO-INJECTION MOLDING: EFFECT OF PROCESSING ON MATERIAL DISTRIBUTION AND MECHANICAL PROPERTIES OF A SANDWICH MOLDED PLATE Selden R Swedish Institute for Fibre & Polymer Research The effect of moulding parameters on material distribution and mechanical properties of co-injection moulded plates was studied using an experimental design method. The plates were moulded with polyamide-6 as skin and a 20% glass fibre-reinforced polybutylene terephthalate(PBTP) as core. Five moulding parameters, i.e. injection velocity, mould temp., skin and core temps., and core content, were varied at two levels. The statistical analysis of the results showed that three parameters, i.e. injection velocity, core temp. and core content, were the most significant in affecting skin/core distribution. A high core temp. was the most significant variable promoting a constant core thickness, while core content was the most significant factor influencing a breakthrough of the core. Mechanical properties, such as flexural and impact strength, showed a high correlation with the skin/core distribution. The slight increase in falling weight impact strength of the sandwich moulded plates, compared with similar plates moulded from PBTP alone, could be explained from the failure process, which initiated in the brittle core and propagated through the ductile skins. 21 refs. EUROPEAN UNION; SCANDINAVIA; SWEDEN; WESTERN EUROPE

Accession no.776371

© Copyright 2002 Rapra Technology Limited

Item 118 Polymer Process Engineering ’97. Conference proceedings. London, July 1997, p.24-31 APPRAISAL OF 2K MOULDING Tinson J Sifam Ltd. (Institute of Materials) Multi-shot injection moulding is a process whereby a number of thermoplastic materials are injected simultaneously, or sequentially, into a mould on a single machine during one machine cycle - the most common form being a two material process, perhaps one material being a soft elastomer. Machines are now available that can inject up to six different materials, a two-material injection process would be called 2K. The different injection methods are explored, with emphasis mainly on a rotating platen 2 or 3K process whereby two or three materials/colours are injected to build up a part. The benefits in product cost and point of sale advantage are discussed with case studies in the field of power tools, mobile phones, domestic appliances, cars and household products. The advantages of such a process in designingin gaskets, soft touch areas, eliminating of printing operations, product colour enhancement and moulded in windows are shown with recent case studies from Sifam. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.775976 Item 119 Polymer Process Engineering ’97. Conference proceedings. London, July 1997, p.2-16 INNOVATIVE INJECTION MOULDING PROCESSES FOR BETTER PRODUCTS Eckardt H Battenfeld GmbH (Institute of Materials) Injection moulding has been known for many decades and has been developed as a process for moulding the full range from very small to very large injection moulding. Modern machine and mould technology in combination with the raw material enable the production of high quality mouldings. The technology has been further developed, modern technologies (CAD/CAE) are increasingly being used. Moulding with thick wall sections create sink marks and tend to warp. Mouldings with flexible and rigid sections made in conventional injection moulding need to be produced in two injection steps and assembled afterwards. Extremely large size mouldings create problems by internal stresses. To overcome the limits of standard injection moulding, innovative processes have been developed, not to compete with but to support standard injection moulding. It is shown that by means of these processes, not only new ideas can be realised but also quality can be improved and costs reduced.

55

References and Abstracts

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.775974 Item 120 Patent Number: US 5899500 A 19990504 STAGED COINJECTION MOLDING PROCESS FOR PRODUCING VARIABLY FLEXIBLE ARTICLES Benvenuto G Ventra Group Inc. A staged coinjection moulding process to produce a vehicular mud guard or similar moulded article having regions of different mechanical properties. The process includes the steps of injecting a relatively small amount of low flexural modulus (flexible) plastic resin to form a skin along the proximal walls of the mould cavity, followed by an injection of high flexural modulus (stiff) plastic resin. Finally, a second injection of flexible resin is introduced into the mould to force the stiff material to the distal region of the mould. This results in the two dissimilar plastic materials having a longitudinal interface to reduce the risk of delamination. CANADA

Accession no.774419 Item 121 Plastics and Rubber Weekly No.1840, 9th June 2000, p.10 PUSHING THE LIMITS OF TWO-SHOT Wacker-Chemie has introduced a self-bonding liquid silicone rubber that can be overmoulded onto most plastics with no need for primers or special tool treatments. The Elastosil LR grade develops only a weak bond to the substrate within the moulding cycle, with the full bond strength developing over a 24-hour post moulding period. This prevents the material bonding to the tooling. Although the bond strength develops slowly, the silicone still cures in less than 30 seconds at mould temperatures between 160C and 180C. WACKER-CHEMIE GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.773715 Item 122 Italian Technology No.1, May 2000, p.44 SPECIAL SOLUTIONS FOR CO-MOULDING PROBLEMS OMF Turra specialises in the production of vertical injection moulding machines for thermoplastic technopolymers. The Pascal series deals with vertical machines with linear or rotary table that offer very effective solutions for overmoulding. The Cigno series is

56

suitable for the overmoulding production of inserts with different dimensions by means of manual or automatic loading. OMF TURRA EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.772641 Item 123 Plastics and Rubber Weekly No.1828, 17th March 2000, p.16 NEGRI JOINS THE 2C LINE-UP With interest growing rapidly in two-colour and twomaterial injection moulding, Negri Bossi has introduced its first ‘standard’ range of machines for multi-material moulding. The CanBiMat Series design places the second injection unit vertically above the fixed platen. The new machine was first shown at Interplas ’99 in an 85 tonne version producing a two-material component using PP for the first material and a TPE for the second. This machine series is a modular extension of the company’s now established Canbio range, which uses field bus technology to provide a distributed control system that is claimed to provide benefits including faster response times, higher reliability, simplification of the electronic system and machine wiring, elimination of analogue equipment, synchronous transfer of information between the elements connected to the bus and scalability. It is the scalability of this distributed control that has been of particular importance for the development of the CanBiMat series. Details are given. NEGRI BOSSI SPA EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.771616 Item 124 TPE’s 2000. Conference proceedings. Philadelphia, Pa., 28th-29th Sept.1999, p.203-16 MULTI-COMPONENT INJECTION MOULDING WITH TPES Tam E; Messina T J-Von Co. (SPE,Thermoplastic Elastomers Special Interest Group; SPE,Philadelphia Section) Thermoplastic elastomers have been used extensively in the consumer, electronics, power tools, horticultural, appliances, telecommunications, personal care products, and sports and leisure markets either as an insert moulding or as an overmoulding substrate in combination with rigid materials. The results are better soft-touch feel, ergonomics and a change of consumer taste preferences in soft versus hard feel. Several classes of thermoplastic elastomers that are designed as insert or overmoulding compound for high impact PS, K-resin, PP, ABS and polyamides such as nylon 6 and 6/6 without the use of

© Copyright 2002 Rapra Technology Limited

References and Abstracts

USA

Agie and Charmilles equipment available. Its CNC department can make electrodes with an accuracy of +/0.002in. ATLAS PRECISION

Accession no.771582

USA

adhesives are discussed. Mechanical properties of these materials are covered. Some typical applications and materials selection are illustrated.

Item 125 British Plastics and Rubber April 2000, p.23-4 LIQUID SILICONE OFFERS THE PLASTIC MOULDER A PERFORMANCE ELASTOMER The injection moulding of liquid silicone rubber is discussed, with particular reference to the use of specially modified injection moulding machines. The characteristics and properties of silicone rubbers are described, and advantages of these properties in applications in end use industries such as automotive, electronic, medical, and household appliances. One area of application driving the growth in their use is the increase in multi-component moulding with which a sealing element can be added to a rigid component in one moulding operation. Machine design modifications are examined. WESTERN EUROPE

Accession no.771105 Item 126 Revista de Plasticos Modernos 78, No.520, Oct.1999, p.450/4 Spanish COINJECTION MOULDING FOR INNOVATIVE PACKAGING Netstal Maquinas SA Coinjection moulding is examined as a method for the production of multi-layer plastics containers, and the use of Netstal’s SynErgy 2C injection presses in such applications is discussed. NETSTAL MASCHINEN AG; HOFSTETTER O.,AG EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN; SWITZERLAND; WESTERN EUROPE

Accession no.768730 Item 127 Injection Molding 8, No.4, April 2000, p.82/5 PRECISE TWO-SHOT TOOLS MAKE THE DIFFERENCE Maniscalco M Atlas Precision is one of the few shops in the US Southeast that can build two-shot tools. About 80% of the tools built go to OEM customers, while the rest are built for its own moulding operation. Applications include soft-touch TPEs on a rigid plastic, two rigid plastic components moulded together and overmoulding of rubber gaskets. In EDM sinker and wire, the company has the highest-accuracy

© Copyright 2002 Rapra Technology Limited

Accession no.768545 Item 128 Polymer Engineering and Science 39, No.11, Nov.1999, p.2159-71 BONDING STRENGTH AT SOLID-MELT INTERFACE FOR POLYSTYRENE IN A SEQUENTIAL TWO-STAGED INJECTION MOULDING PROCESS Huang D Y; Chen R S Taiwan,National Cheng Kung University A theoretical model for the degree of bonding at the solidmelt interface for a two-stage injection moulding process for PS was proposed. This model accounted for the cooling profile through the thickness of the part and the interpenetration depth of polymer chains across the interface. By fitting experimental results to the model, an inter-relationship between the average extent of reaching an effective interpenetration depth and the degree of bonding was obtained. This model would be useful in CAE analysis for a two-staged injection moulding process in which residual stress, distortions or fractures might occur at the surface. 15 refs. TAIWAN

Accession no.768137 Item 129 Schwertberg, c.2000, pp.8. 30cms. 14/3/2000 MOULD MAKING : MOULDS BY ENGEL Engel GmbH Engel presents information on its mouldmaking services, which encompass customer consultation, computer-aided mould development and design, mould manufacture and machining, and mould trials. Moulds can be built for multicomponent, multicolour and high-precision parts, while moulds for medical engineering parts are manufactured in compliance with cleanliness regulations. Engel can also produce moulds for liquid silicone rubber parts, which require highly accurate machining and precise temperature control for perfect mouldings. AUSTRIA; EUROPEAN UNION; WESTERN EUROPE

Accession no.767527 Item 130 Nafels, 1997, pp.16. 30cms. 14/3/2000 SYNERGY 2C. ALL GOOD THINGS COME IN TWOS! 2C BY NETSTAL. THE OPTIMAL SOLUTION FOR TWO-COMPONENT APPLICATIONS NETSTAL MACHINERY LTD.

57

References and Abstracts

Information is presented on the SynErgy 2C range of machinery from Netstal. The injection moulding machines feature two injection units for the production of twocolour or two-component plastic products, and are characterised by their speed, reliability, precision, userfriendliness and economic efficiency. SynErgy 2C machines are suitable for all over-moulding processes as well as co-injection and bi-injection, and allow free choice between simultaneous, time-delayed or sequential injection. High process constancy on both injection units is possible by means of Sycap closed loop process control. Details are given of rotary plate, sliding and transfer overmoulding techniques, while the principles of co-injection and bi-injection are also outlined. SWITZERLAND; WESTERN EUROPE

Accession no.767523 Item 131 Modern Plastics International 30, No.2, Feb.2000, p.19 FORD REDUCES COSTS WITH EIGHT SANTOPRENE TPE PARTS Ford is using components engineered with hard/soft material combinations to consolidate several parts and reduce costs on the new Ford Focus, it is briefly reported. Parts made from Santoprene thermoplastic elastomer bonded to rigid nylon or PP employ new multi-material processing technologies where two or more compatible materials are injection moulded in one moulding cycle. FORD MOTOR CO. USA

Accession no.766778 Item 132 Kunststoffe Plast Europe 90, No.2, Feb.2000, p.32-3 SILICONE COMPOSITES Pohmer K The development of innovative self-adhesive liquid silicones has made it possible, for the first time, to produce rigid/flexible composites in thermoplastics and silicones using hardened steel moulds without any coating. WACKER-CHEMIE GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.764600 Item 133 Plastics News International Jan./Feb.2000, p.16 VARIETY KEY TO SUCCESS OF ERGOTECH MULTI-COMPONENT MACHINES Demag Ergotech is reported here to expect that its “Ergotech multi” series will have accounted for over 20 percent of the multiple injection units sold by European

58

manufacturers during 1999. This article takes a close look at the company’s multi-component injection moulding machines. DEMAG ERGOTECH AUSTRALIA; EUROPE-GENERAL

Accession no.762997 Item 134 Emerging Plastics Materials and Process Technologies for Automotive Interiors. Conference proceedings. Detroit, Mi., 21st May 1998, paper 7 MULTICOMPONENT INJECTION MOULDING TO ENHANCE PRODUCT, REDUCE COST Hare R B Ferromatik Milacron GmbH (SPE,Automotive Div.) Injection moulding with multiple colour resins began several decades ago with multi-colour moulding of typewriter keys to produce indelible characters on the keys. Today, the technology has advanced to the use of multiple materials, improving the fit and feel of many products, including automotive interior components, and enabling creation of precision articulating assemblies ‘in the mould’. While the basic technology has been around for some time, it is not well understood or widely used in the US because most of the applications are in proprietary manufacturing sites. However, the percentage of moulding machines produced with multiple injection units at one leading European manufacturer has quadrupled over the last eight years, indicating greater interest in, and application of, multi-colour/material capability. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.758948 Item 135 Plast’ 21 No.85, Oct.1999, p.111-3 Spanish COINJECTION MOULDING FOR INNOVATIVE PACKAGING Kudlik N Netstal AG The principles of coinjection moulding and its use in the production of multi-layer plastics packaging items are examined. Technical features of machinery used in this process are discussed, with particular reference to the SynErgy 2C machine manufactured by Netstal. HOFSTETTER O.,AG SWITZERLAND; WESTERN EUROPE

Accession no.758826 Item 136 Composites-French/English No.36, Nov./Dec.1999, p.48-9

© Copyright 2002 Rapra Technology Limited

References and Abstracts

BATTENFELD INJECTION MOULDING TECHNOLOGY IN STATE-OF-THE-ART APPLICATIONS Battenfeld’s Airmould gas-assisted injection moulding process has been used successfully to process reinforced thermoplastic materials. Typical examples are exterior door handles made from glass fibre-reinforced nylon 6. The process makes it possible to produce hollow sections, and thus mouldings with high impact strength and a good surface appearance. Multi-component injection moulding makes it possible to combine highly reinforced materials with non-reinforced ones. An example is a stand for hot pots produced by combining a 30% glass fibre-reinforced polyamide with liquid silicone rubber. BATTENFELD AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.756649 Item 137 Modern Plastics International 29, No.12, Dec.1999, p.29-30 ROTARY STACK MOULD TECHNOLOGY EXPANDS OVERMOULDING OPTIONS Mapleston P Injection machine maker Ferromatik Milacron and mould technology developer Gram Technology have agreed to exploit multicomponent overmoulding stack mould technology. Ferromatik Milacron already works with mouldmaker Foboha which has developed similar technology. Demag Ergotech has demonstrated the concept for production of reclosable spouts for beverage cartons using a mould built by Gram. Hekuma Herbst Maschinenbau has taken a different approach on twocomponent moulding. Its philosophy is to move parts from one cavity to another by robot, rather than using rotating platens or moulds. FERROMATIK MILACRON GMBH; GRAM TECHNOLOGY; FOBOHA; DEMAG ERGOTECH GMBH; HEKUMA HERBST MASCHINENBAU GMBH DENMARK; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; SCANDINAVIA; WESTERN EUROPE

Accession no.756529 Item 138 Kunststoffe Plast Europe 89, No.9, Sept.1999, p.39-41 INCREASING FUNCTIONALITY THROUGH OVERMOULDING Kuhmann K; Drummer D; Ehrenstein W Erlangen-Nurnberg,University Overmoulding as a technique to improve functionality of a component is examined. It provides the ability to integrate conductivity and magnetic properties directly into the moulded part. The use of functional fillers is

© Copyright 2002 Rapra Technology Limited

described, and their effect on bond strength. 7 refs. (Translated from Kunststoffe, 89, (1999), 9, pp.112-6). EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.755377 Item 139 Kunststoffe Plast Europe 89, No.9, Sept.1999, p.29-31 NEW MULTI-COMPONENT INJECTION MOULDING PROCESSES Jaeger A Demag Ergotech GmbH Examples are given of designs of moulds and process technology for the production of multi-component injection moulded products, with particular reference to developments from Demag Ergotech. Details are given of new rigid/flexible composites, three-dimensional moulded interconnect devices, combinations with inmould sheet lamination and new mould concepts, which offer greater efficiency and further potential fields of application. (Translated from Kunststoffe, 89, (1999), 9, pp.85-89). EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.755372 Item 140 Materie Plastiche ed Elastomeri 64, No.9, Sept.1999, p.552/68 Italian SAVINGS WITH MULTI-INJECTION MOULDING Baucia G A survey is made of machinery manufactured by a number of companies for multi-material and multi-colour injection moulding. MIR SPA; PRESMA SRL; ENGEL; DEMAG ERGOTECH; NETSTAL MASCHINEN AG; OIMA SPA; KRAUSS-MAFFEI KUNSTSTOFFTECHNIK GMBH; BMB SPA; BATTENFELD GMBH; ARBURG MASCHINENFABRIK; BM BIRAGHI; DR.BOY GMBH AUSTRIA; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; ITALY; SWITZERLAND; WESTERN EUROPE

Accession no.754682 Item 141 Materie Plastiche ed Elastomeri 64, No.9, Sept.1999, p.542/6 Italian ROTARY MACHINES: THOSE WHO TRY THEM BUY THEM Latorre C The use of rotary injection presses in the manufacture of two-component and foamed products is examined, and a

59

References and Abstracts

number of examples are presented of parts moulded using rotary machines produced by Presma of Italy. Developments by the Company in horizontal and vertical machines for multi-colour and multi-material injection moulding and insert moulding are also reviewed. PRESMA SRL EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.754680 Item 142 Materie Plastiche ed Elastomeri 64, No.9, Sept.1999, p.534/40 Italian MULTI-COLOUR OR MULTI-MATERIAL, BUT DON’T CALL IT SPECIAL Latorre C Details are given of Engel’s Combimelt range of standard injection presses which are equipped with suitably adapted injection units and other components for multi-colour and multi-material injection moulding. Developments in computer control systems, industrial robots and electric presses are also examined. ENGEL; ENGEL ITALIA AUSTRIA; EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.754679 Item 143 British Plastics and Rubber Nov.1999, p.12 FERROMATIK TAKES IN NEW TECHNOLOGIES Ferromatik Milacron has signed up to offer two emerging injection moulding technologies. It has taken a licence for the Trexel MuCell microcellular foam process, and has joined in a cooperation with Gram Technology for its multi-component overmoulding stack mould technology. The MuCell licence gives Ferromatik the ability to sell new machines or convert existing machines of its own or anyone else’s manufacture. MuCell is a technique for moulding components with a uniform microcellular structure of cells generally 5-50 microns in diameter. The structure is created by dosing the melt with supercritical fluids of carbon dioxide or nitrogen, reducing weight, stress, warpage, sink marks and hold time. The resultant reduction in melt viscosity also lowers fill pressure by 50% and required clamp tonnage by 40%. The cooperation between Ferromatik Milacron and Gram Technology appears to clarify the confusion over the rotating centre plate technology. Details are given. FERROMATIK MILACRON GMBH; GRAM TECHNOLOGY EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.753940

60

Item 144 Nova-Pack Americas ’99. Conference proceedings. Orlando, Fl., 1st-2nd Feb.1999, p.293-305 MULTI-MATERIAL PREFORM MOULDING: NEW TECHNOLOGIES FOR LOWER COST PREFORMS FOR BEER Halsall K; Rao R Husky Injection Molding Systems Ltd. (Schotland Business Research Inc.) The potential for growth in the PETP industry will be fuelled by innovative technologies that enhance PETP’s capability to the meet the needs of the beer industry. Initially the consumer will drive the conversion to PETP regardless of the barrier performance and cost, because they like the package. However to have a significant penetration into this market, PETP containers will need not only improved barrier properties, but also costs that compete with existing glass and metal containers. The current technologies for multilayer preforms are reviewed, the variables that impact cost examined and a solution for economic production is identified. CANADA

Accession no.753888 Item 145 Netstal News No.35, May 1999, p.13-5 CO-INJECTION FOR INNOVATIVE PACKAGING PRODUCTS. Kudlik N Netstal AG The use of coinjection moulding techniques for the production of packaging is discussed, and the advantages offered by the use of machines from Netstal in their SynErgy 2C series are described. The use of coinjection techniques for multi-layer, barrier layer and recycled content constructions is examined, and in particular, the production of coinjected PETP preforms with five and three layers is detailed. SWITZERLAND; WESTERN EUROPE

Accession no.753019 Item 146 Plastics Technology No.10, Oct.1999, p.54/61 LIQUID INJECTION MOLDING HITS ITS STRIDE Ogando J Growth in the use of liquid injection moulding as a processing method is examined, as suppliers in North America report sales growth in liquid silicone rubber in excess of 10% a year, and producers of liquid injection moulding machines also report a similar picture of double digit growth. Trends and developments driving this growth are discussed, and include the ability to mould

© Copyright 2002 Rapra Technology Limited

References and Abstracts

bigger parts, the availability of higher mould cavitation, gas-assist moulding, the possibility to produce dualdurometer parts and thermoset/thermoplastic combinations. Developments in machinery are reviewed with details of specific machines. NORTH AMERICA

Accession no.752983 Item 147 Injection Molding 7, No.11, Nov.1999, p.62 SELF-ADHESIVE SILICONES ARE STUCK ON ETPS Kirkland C Wacker-Chemie has developed a special class of liquid silicone rubber that is helping to drive liquid silicone rubber/engineering thermoplastic multi-material moulding in automotive and other industries. They are formulated to process the same as conventional LSRs, but unlike conventional silicones, these self-adhesive silicones stick to the engineering thermoplastic substrate, yet not to the mould. Brief details are given of grades of Elastosil liquid silicone rubbers, and typical commercial applications are indicated. WACKER-CHEMIE GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.752964 Item 148 Plastiques Flash No.312, June/July 1999, p.122-5 French TABLE OF HOT RUNNER SYSTEMS Technical data are presented for hot runner injection mould systems manufactured by 21 companies. WORLD

Accession no.752753 Item 149 Plastics News International Oct.1999, p.56/60 DEVELOPMENTS IN MULTI-COMPONENT INJECTION MOULDING With 25 years experience in multi-component injection moulding, Battenfeld can now offer the machines and nozzle technology to suit a wide range of applications. The process can be used to manufacture parts combining solid material with foamed material and also two solid materials. Even the permeability of the plastic part can be tailored to specific requirements using barrier materials in the core. Machine and process technologies are discussed. BATTENFELD AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.751265

© Copyright 2002 Rapra Technology Limited

Item 150 Plastics and Rubber Weekly No.1805, 24th Sept.1999, p.9 INNOVATION IS THE THEME At this year’s Interplas, there will be a strong focus on high productivity and high precision production systems. Two-component injection moulding technology will be in evidence throughout the exhibition. Arburg will be showing production of a two-colour cup, while Engel will demonstrate a 125 tonne machine moulding a hard/soft combination. Sumitomo will be present at Interplas for the first time with its all-electric machines. Engel will be running the first public demonstration of Trexel’s MuCell microcellular foam moulding technology. WORLD

Accession no.751259 Item 151 155th ACS Rubber Division Meeting, Spring 1999. Conference Preprints. Chicago, Il., 13th-16th April 1999, Paper 80, pp.18 MULTI-COMPONENT INJECTION MOLDING OF RIGID-FLEXIBLE COMBINATIONS MADE FROM THERMOPLASTICS, RUBBER AND LIQUID SILICONE RUBBER Ronnewinkel C; Haberstroh E IKV (ACS,Rubber Div.) Factors influencing adhesion between rubber and thermoplastic components in parts produced by twomaterial injection moulding are examined. Results are presented of studies undertaken to optimise adhesion in parts produced by this technique from liquid silicone rubber and polyamides or PBTP. 22 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; USA; WESTERN EUROPE

Accession no.749891 Item 152 British Plastics and Rubber Oct.1999, p.23-4 THINWALL PACKAGING STRETCHES THE LIMITS FOR COINJECTION Kudlik N Netstal AG Developments in multilayer packaging are fuelled by requirements for longer shelf life and the ability to substitute expensive packaging materials with plastics. By adding a barrier layer, the oxygen permeability is reduced and shelf life extended. The best known coinjection application in the packaging field is probably the PETP bottle preform. The principles of coinjection, together with machine and mould requirements are discussed. SWITZERLAND; WESTERN EUROPE

Accession no.749221

61

References and Abstracts

Item 153 British Plastics and Rubber July/Aug.1999, p.26-7 SOFT TOUCH RAMPS UP INTEREST IN MULTIMATERIAL MOULDING

Item 156 Plastics and Rubber Weekly No.1798, 6th Aug.1999, p.10 IDEAS STACK UP OVER TWO-SHOT PRODUCTION

Multi-material moulding is discussed with reference to trends in soft touch products and machine developments by Arburg. The use of a soft-touch thermoplastic elastomer to the basic moulding to give improved quality perception is a current trend in injection moulded products. Technical considerations involved in adding a thermoplastic elastomer to a hard elastomer are discussed in terms of handling and processing, and mould design. ARBURG MASCHINENFABRIK

Technology for the production of two-component mouldings which use stack mould technology to double the output of an injection moulding machine is discussed, with reference to patents filed by Ferromatik and Foboha and by Gram Technology of Denmark. Both systems involve a stack mould configuration with two parallel parting lines arranged one behind the other. One carries the cavities for the preform mouldings, and the other the cavities for overmoulding the finished parts. Transfer of preform mouldings to overmoulding cavities is achieved by rotating the centre plate around its vertical axis. Applications in PP/PE carton closures are described. FERROMATIK MILACRON; FOBOHA; GRAM TECHNOLOGY; DEMAG ERGOTECH

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.747532 Item 154 Kunststoffe Plast Europe 89, No.7, July 1999, p.7-8 OVERMOULDING WITH A SINGLE INJECTION UNIT. A DEVELOPMENT OF THE MONOSANDWICH PROCESS Jaroschek C; Steger R Bielefeld,Fachhochschule; Ferromatik Milacron Maschinenbau GmbH A new version of the monosandwich process for overmoulding using a single injection unit is described. Suitable machinery for overmoulding is described, machines with one injection unit and two extruders are discussed and the monosandwich 5 process is outlined. (German version of this paper, which includes tables, is on p.38-9) EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.747370 Item 155 Plastics News International Sept.1999, p.46-7 NOVEL TECHNIQUE FOR TWO-COMPONENT PARTS DOUBLES OUTPUT A patented preform transfer technique applied to twocomponent injection moulding doubles the number of cavities for a given mould size. In the Gram technique, jointly developed by Demag Ergotech and Gram Technology, the mould is similar to a stack mould. It has two parallel parting lines at which the cavities for the preforms and finished mouldings are arranged. The transfer of the preforms is achieved by rotating the middle plate about its vertical centreline. The concept has been demonstrated in the production of reclosable spouts for beverage cartons consisting of a PE boss and a PP screw cap. DEMAG ERGOTECH GMBH; GRAM TECHNOLOGY DENMARK; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; SCANDINAVIA; WESTERN EUROPE

Accession no.747164

62

DENMARK; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; SCANDINAVIA; WESTERN EUROPE

Accession no.745478 Item 157 Modern Plastics International 29, No.9, Sept.1999, p.50/2 MULTIMATERIAL TECHNOLOGY COMES TO THERMOSET LIQUID PROCESS Snyder M R A brief review is presented of liquid injection moulding machines manufactured by leading US producers. There is claimed to be ‘explosive’ growth in this market, once only considered to be a peripheral production process. Particular details are given of Engel’s multimaterial liquid injection moulding machine. USA

Accession no.745191 Item 158 Molding Systems 57, No.8, Aug.1999, p.34-8 MANIFOLD IMPROVEMENTS Destefani J D Developments and trends in automotive air-intake manifolds are reviewed. The switch from metal to plastic air intake components is discussed in terms of the advantages it affords in design, manufacture, production costs, and performance. Injection moulded nylon air intake systems offer weight reduction, parts consolidation and improved engine performance. This latter, is because the smooth inner walls of injection moulded nylon manifolds offer improved air flow, and nylon’s low thermal conductivity insulates the air inside the manifold from engine heat and allows high density intake air to flow into the engine. The use of lost-core injection moulding techniques or alternatively welding techniques

© Copyright 2002 Rapra Technology Limited

References and Abstracts

are also examined, and particular technical advances such as UBE’s die rotary injection moulding process, hot-plate welding, and integrated air and fuel modules are described. USA

Accession no.742655 Item 159 Rubber World 220, No.3, June 1999, p.35-7 COINJECTION MOULDING FOR LIQUID SILICONE RUBBER Timmerman J Engel GmbH Coinjection moulding is an exciting new process for the moulding of liquid silicone rubber that opens up new possibilities. Coinjection involves injecting two or more similar materials into the mould cavity together. One material forms the skin and the other forms the core. The process is described, together with equipment requirements and design considerations. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.739157 Item 160 Asian Plastics News May 1999, p.13 English; Chinese NOVEL TWIST FOR OVER-MOULDING Vink D It announced here that injection moulding machine manufacturer, Ferromatik Milacron, and tool-maker Foboha, have developed an innovative system that allows multi-component injection moulding to be carried out on smaller machines. Full details of the development are provided. FERROMATIK MILACRON; FOBOHA EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.737697 Item 161 Injection Molding 7, No.5, May 1999, p.143 NEW PRODUCT SHOWCASE - PIVOTING CENTER PLATEN OPTIMIZES MULTISHOT MOLDING In this article, a new pivoting centre platen with two mould-mounting faces is highlighted. The platen is made by Milacron Inc. of the USA, to replace large platens with turntables normally used in multi-shot moulding. It allows the moulding of larger parts on smaller, more economical machines. Full details are given. MILACRON INC.

© Copyright 2002 Rapra Technology Limited

USA

Accession no.737648 Item 162 Injection Molding 7, No.5, May 1999, p.77-8 TOOLING - CONTEMPLATING COINJECTION? Sloan J This article discusses the benefits of coinjection moulding, looking in particular at the case of moulding the interior door handles of the Daimler-Chrysler mini-van. SeigelRobert Inc. who manufactures the handles invested in a Battenfeld coinjection machine to do the job. Full details are given. SEIGEL-ROBERT INC.; BATTENFELD OF AMERICA INC. USA

Accession no.737630 Item 163 Modern Plastics International 29, No.7, July 1999, p.77-8 NEW COINJECTION DESIGNS ADD APPLICATIONS POTENTIAL Toensmeier P A; Hilpold L Recent developments in machines, materials and design concepts have increased the flexibility of the coinjection moulding process, expanding part-design potential. One recent application is an interior door handle for the 1999 DaimlerChrysler minivan. By coinjecting a 33% glassfilled core of nylon 6 with a neat nylon 6 surface, SiegelRobert was able to combine high aesthetics with the structural performance the part required. WORLD

Accession no.737467 Item 164 Plast’ 21 No.76, Dec.1998, p.14 Spanish SANDRETTO BN MULTI-MELT SYNCRO DUAL INJECTION PRESS An examination is made of Sandretto’s Multi-Melt Syncro coinjection moulding technology and technical features and modes of operation of the BN Multi-Melt Syncro dual injection press developed by the Company for use in all types of coinjection moulding processes. SANDRETTO INDUSTRIE SPA EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.736250 Item 165 Plastics News(USA) 11, No.10, 26th April 1999, p.18/20

63

References and Abstracts

MULTIMATERIAL MOULDING CATCHING ON IN US Bregar B Multimaterial or multicolour moulding is being used to produce electric car tail lights, toothbrushes and buttons for dashboards. The technology has been commonplace in Europe for many years and is now a rapidly growing market segment in the US. Soft-grip demand is also driving multimaterial moulding, with a flurry of new screwdrivers, can openers and toothbrushes that fuse hard plastics with thermoplastic elastomers.

29, No.5, May 1999, p.30-1 COINJECTION EXPANDS DESIGN OPTIONS IN A RANGE OF PARTS Toensmeier P A This article discusses the process and benefits of coinjection moulding, which it is expected will find growing use, following recent developments in materials and machinery which have expanded the process’s applications potential. Examples are provided. BATTENFELD; SIEGEL-ROBERT INC.; MILACRON; ENGEL; NISSEI

USA

EUROPE-GENERAL; JAPAN; USA

Accession no.736143

Accession no.733539

Item 166 Plastverarbeiter 48, No.6, 1997, p.62-3 German TURN, RESHAPE, PUSH ... Theiss E

Item 169 Antec ’99. Volume 1. Conference proceedings. New York City, 2nd-6th May,1999, p.539-44. 012 COMBINING LIQUID-SILICONE-RUBBERS WITH THERMOPLASTICS TO RIGIDFLEXIBLE COMBINATIONS USING 2COMPONENT INJECTION MOULDING Ronnewinkel C; Haberstroh E Institute for Plastics Processing (SPE)

Here in part II in this series of articles on turning, reshaping and extrusion topics cover turntable applications. The article to be manufactured determines first and foremost which tooling technique is to be applied during multicomponent injection moulding. The different tools available are compared along with their applications, including ejection processes. KRAUSS MAFFEI EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.735815 Item 167 Plastics and Rubber Weekly No.1789, 4th June 1999, p.7 MULTI-SHOT VALUES Coates P Bradford,University Multi-shot moulding, using either two materials or colours, offers great potential to manufacturers and can add value for moulders. Mould technology is particularly important in multi-shot moulding, where moulds are normally more intricate, having rotating or sliding sections. The technology means that assembly costs can be reduced or eliminated. Various configurations of machine are feasible: choices include configuration of injection units, automated handling requirements, type of tooling and clamp force requirement. NETSTAL UK LTD.; ENGEL UK LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.735540 Item 168 Modern Plastics International

64

The production of components consisting of flexible silicone rubber bonded to rigid thermoplastics using twocomponent injection moulding techniques is discussed. The strength of the bond at the interface between a polyamide and silicone rubber was investigated using an injection moulded tensile test bar. It was concluded that such components could replace rubber-metal combinations for certain applications. 15 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.732951 Item 170 Antec ’99. Volume 1. Conference proceedings. New York City, 2nd-6th May,1999, p.481-4. 012 EFFECT OF THE SKIN/CORE RATIO ON THE FLOW BEHAVIOUR DURING CO-INJECTION MOULDING Derdouri A; Garcia-Rejon A; Nguyen K T; Simard Y; Koppi K A; Salamon B A Canada,National Research Council; Dow Chemical (SPE) The effect of the core:skin ratio on the overall flow behaviour in the co-injection moulding of a rectangular plaque was studied. ABS was used for both the skin and the core, whilst polycarbonate was used only for the skin. A black pigment was added to the core to make it visible. The results are discussed in terms of relative viscosities, injection speed, melt and mould temperatures. 14 refs. CANADA; USA

Accession no.732940

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Item 171 Plastics in Canada Feb.1999, p.13-5 MULTI-MATERIAL INJECTION MOULDING This article discusses multi-material injection moulding machines, explaining that a two-platen machine has several benefits, as a result of its design. It then highlights several new machines from well-known manufacturers, such as Van Dorn Demag, Cincinnati Milacron, and JSW Plastics Machinery Inc. BATTENFELD OF AMERICA; VAN DORN DEMAG; CINCINNATI MILACRON; JSW PLASTICS MACHINERY INC.; INCOE CORP. CANADA; EUROPE-GENERAL

Accession no.732908 Item 172 Polymer Plastics Technology and Engineering 38, No.2, 1999, p.241-54 SIMULATION OF FILLING PATTERN OF MULTI-COMPONENT INJECTION MOULDING Sahu R; Yao D; Kim B Amherst,Massachusetts University Multi-component injection moulding is a sequential process in which one plastic material (overmould) is moulded onto a previously filled and solidified plastic part (substrate). This innovative manufacturing process is gaining popularity among plastic manufacturers because of its flexibility and potential to produce multifunctional plastic parts. In contrast with increasing popularity, an integrated computer simulation software for this process is currently unavailable, partially because of the difficulty in mapping the boundary between the substrate and the overmould. Multi-component moulders are still using the trial-and-error approach while computer aided engineering prevails in conventional injection moulding practice. When the flow pattern of the overmould is of interest, it may be justifiable to use the conventional mould filling simulation to predict the pattern. It is postulated that the influence of the interface boundary on the flow pattern of the overmould is insignificant due to the high filling rates normally encountered in the multi-component injection moulding process. The flow patterns of the overmould of the handle of Gillette’s shaving razor for ladies are predicted based on an approach where an integrated filling-packing-cooling simulation is first run for the substrate; upon completion of the substrate cooling, the substrate surface temperature is used as the initial boundary condition for the overmould in the second-stage analysis. Boundary interface techniques are applied to map the boundary condition from the substrate to the overmould. The predicted flow pattern is found to be in reasonably good agreement with that obtained using the conventional injection moulding simulation as well as with the experimental results. 13 refs. USA

Accession no.732326

© Copyright 2002 Rapra Technology Limited

Item 173 Journal of Elastomers & Plastics 31, No.2, April 1999, p.143-61 COINJECTION MOULDED PREGENERATED MICROCOMPOSITES McLeod M A; Baird D G Virginia,Polytechnic Institute & State University The coinjection moulding of PETP reinforced with pregenerated thermotropic liquid crystalline polymer (TLCP) fibrils, where the TLCP (DuPont, HX1000) has a higher melt processing temperature than PETP, is described. A novel dual extrusion process is used to spin strands of PETP reinforced with HX1000 fibrils. The strands are compression moulded into cartridges and then coinjection moulded to form plaques. In comparison to conventionally injection moulded pregenerated microcomposites, coinjection moulded composites have higher flexural moduli. The coinjection moulded composites also have smoother surfaces than glass fibrefilled PETP. It is determined that the best mechanical properties are achieved using a core of glass fibre-filled PETP. 27 refs. USA

Accession no.732309 Item 174 Plastics News(USA) 11, No.11, 3rd May 1999, p.13 BEMIS CENTERING ON COINJECTION MOULDING Toloken S Judging by the winners of a recent plastics design competition, gas-assisted injection moulding and reaction injection moulding seem to be the methods of choice for cutting-edge moulding. However, Bemis, executive vice president of Bemis Manufacturing in Sheboygan Falls, Wis., is betting on coinjection moulding. Bemis, and its Kelch subsidiary in Cedarburg, Wis., plan to add five more coinjection machines by midsummer, an increase from eight now. And Bemis is considering buying a 6,600 ton coinjection press, which it says would be the world’s largest. Bemis declined to release details of that large machine. The process puts recycled material in a core of a moulded piece, a prospect that the company says is one of the most interesting things about coinjection. Details are given. BEMIS MANUFACTURING CO. USA

Accession no.731734 Item 175 Plastics Technology 45, No.5, May 1999, p.39-40 WHAT’S BEHIND THE CHROME PLATE? Ogando J Siegel-Robert, best known as the world’s largest electroplater of plastics, is discussed in terms of its

65

References and Abstracts

polyamide/PP specimens was mainly viscous finger formation. Injection moulding was done with a 110 ton K110 S 2F machine from Ferromatix Milacron. It had two injection units. Potential for using recycled polymers as core material is pointed out. 25 refs.

expertise in injection moulding techniques. The company moulds automotive, consumer and appliance parts using advanced moulding technologies such as coinjection, gasassist and rotary multi-shot moulding, and examples are given of projects involving these techniques. SIEGEL-ROBERT INC.

SCANDINAVIA; SWEDEN; WESTERN EUROPE

USA

Accession no.729191

Accession no.731650 Item 176 Antec ’99.Volume 1.Conference proceedings. New York City, 2nd-6th May 1999, p.406-10 .012 CASE STUDY FOR MULTI-SHOT Hahn J MGS Enterprises Inc. (SPE) The injection moulding of a concept part was studied, using injection moulding machines equipped with two separate injection units. Six different manufacturing methods were considered and the process advantages and disadvantages, capital cost, cycle time and cost per piece are evaluated for each method. USA

Accession no.731028 Item 177 Journal of Injection Molding Technology 2, No.4, Dec.1998, p.166-75 COINJECTION MOULDING. COMPATIBILISATION OF POLYAMIDEPOLYPROPYLENE SANDWICH STRUCTURES Selden R Swedish Institute for Fibre & Polymer Research Sandwich plates were coinjected from polyamide 6 (Durethan B 30S from Bayer) and talc-filled PP (Hostacom M2 U01 from Hoechst). The polyamide skin was coloured black with 1% masterbatch, to identify the interface between the materials. Mechanical properties were studied as a function of compatibiliser (Orevac CA 100 maleic anhydride grafted PP from AtoChem) concentration. The compatibiliser, was blended with the PP granulate before injection moulding. The properties evaluated included flexural modulus and flexural strength parallel and perpendicular to flow, and falling weight impact strength. The adhesion between skin and core as a function of compatibiliser content was measured by a peel test. The addition of a relatively low concentration of compatibiliser is adequate for obtaining a sufficient degree of adhesion between skin and core and a corresponding improvement of mechanical properties. It is shown that unmodified polyamide/PP sandwich specimens can display a relatively high strength, and modulus. This is mainly explained by the special interface instability formed during the mould filling, giving mechanical interlocking between the two phases. The type of interface instability observed in the unmodified

66

Item 178 TPE ’98. Conference proceedings. London, 30th Nov.-1st Dec.1998, paper 16. 6127 PRACTICAL APPLICATIONS IN TOOLING, INJECTION MOULDING TECHNIQUES Pokorny P Engel Austria Ltd. (Rapra Technology Ltd.; Plastics & Rubber Weekly) There is a wide range of possible applications for thermoplastic elastomers in multi-component parts. This particular market is forecast to rapidly increase over the next few years. It is important that designers, mouldmakers, and mould and machine suppliers work together. Aspects covered include bonding of TPEs to other thermoplastics, material combinations, mould technologies in multi-component injection moulding and design of multi-component injection moulding machines. AUSTRIA; WESTERN EUROPE

Accession no.729083 Item 179 Modern Plastics Encyclopedia 75, No.12, 1998, p.D92 MULTISHOT MOULDING CUTS SECONDARY STEPS, PRODUCES UNIQUE FEATURES Reis T P GW Plastics Inc. Multicomponent or multishot injection moulding combines polymers from two or more independently controlled injection units, delivered in sequence through separate injection nozzles. Increased demand for products with soft-touch, tactile surfaces, as well as part consolidation and increased function, is responsible for its continued growth. USA

Accession no.728676 Item 180 Plastverarbeiter 48, No.3, 1997, p.46-8 German TURN, CONVERT, PUSH ... Theiss E Which mould technique happens to be used in multicomponent injection moulding is determined by this series of articles. In the current article the technique of turning with a turntable is examined with full diagrams. The

© Copyright 2002 Rapra Technology Limited

References and Abstracts

positive and negative aspects of using this technique are discussed. On the positive side, each cycle produces a complete part; complicated ejection techniques are possible; and, cooling agents and hydraulic oil can be fed to the mould through a rotating distributor. On the negative side, the investment in a turntable is rather high; two complete mould ejection sides are needed; and, the lifting force area or surface is often asymmetric, giving rise to increased locking pressure. KRAUSS-MAFFEI EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.726976 Item 181 Kunststoffe Plast Europe 89, No.3, March 1999, p.10-11. (Translated from Kunststoffe 89 (1999) 3, pp.40-4) DESIGN OF ANGLED HOT-RUNNER SYSTEMS Palfinger M; Langecker G; Peinhopf W Institut fuer Kunststoffverarbeitung The production of multicomponent injection moulded parts in multi-cavity moulds is examined, in which rightangled feed with hot runner manifolds of equal length is not always possible. Experiments and simulation are used to demonstrate that with a multi-component index-plate mould with angled melt feed, with equal manifold lengths, the melt flow is improved in the more acutely angled runner. AUSTRIA; WESTERN EUROPE

Accession no.726374 Item 182 Popular Plastics and Packaging 44, No.2, Feb. 1999, p.70-2 COINJECTION BOOSTS BARRIER PROPERTIES OF PET BOTTLES - A REPORT Trends and developments in coinjected PETP bottles are described, with reference to the advantages afforded by the process in terms of barrier properties. Some details of the market size and growth rates are included, and suppliers of resins, machinery and moulds are reviewed. WORLD

Accession no.726347 Item 183 Kunststoffe Synthetics No.10, 1998, p.20-1 German MULTI-COMPONENT INJECTION MOULDING: FROM THE BEGINNING Widmer A The article reviews the development of the Billion company since its foundation in 1949. The company produced its first hydraulic injection moulding machines

© Copyright 2002 Rapra Technology Limited

in 1950. In 1961 it filed its first patents for two component injection moulding machines. In 1968 a range of machines with electric steering was brought out. In 1974 the company produced the world’s biggest two component machine. In 1998 Billion became part of Mannesmann Plastic Machinery. Billion also makes machinery with touch-sensitive screen technology which can even be used by colour blind people. 5% of turnover goes into research and development. Billion produces 97 varieties of injection moulding machines, with 11 closing forces from 90 to 2,200 tonnes, 16 plate dimensions and 13 injectors. BILLION; MANNESMANN PLASTIC MACHINERY EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.724034 Item 184 Kunststoffe Synthetics No.2, 1998, p.16-8 German TRACK FREE MULTIPLE DESIGNS FOR SHAPING PREFABRICATED PARTS Gattringer R In one step, Engel’s Combimelt Technology joins two or more plastics to multi-functional building parts. This multi-component and multi-coloured injection moulding technology is used for the fascias of mobile phones. Fascias are widely responsible for the introduction of this technology. The process enables optimal cost production and hard-soft connections. Combining different materials in the machine considerably improves the functionality of plastic parts. Soft TPE parts are used for better grip. ENGEL MASCHINENBAU GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.724015 Item 185 European Plastics News 26, No.3, March 1999, p.31 NOVEL TWIST FOR OVER-MOULDING Vink D The design is described of a new system for multicomponent injection moulding co-developed by Ferromatik Milacron and Foboha. The design is claimed to aim to retain the advantages of rotary systems for overmoulding, while overcoming some of their disadvantages. The approach involves the use of a stack mould arrangement with the central platen mounted on a turntable that rotates about a vertical axis parallel to the platens. FERROMATIK MILACRON; FOBOHA WESTERN EUROPE

Accession no.720590

67

References and Abstracts

Item 186 Modern Plastics International 29, No.3, March 1999, p.96-8 COINJECTION STEERS TOOL DESIGN FOR PETP BOTTLES Gabriele M C Coinjection has emerged as the leading edge for preform tools and blow moulds used to process PETP bottles. Enhanced barrier capabilities is the thrust behind coinjection technology. Kortec will deliver a 48-cavity coinjection tool in Q3 for a North American processor. The tool will run on a 300-tonne GL 300 injection press moulding preforms for beverage bottles. WORLD

Accession no.719676 Item 187 Polymer 40, No.11, 1999, p.3119-45 STRUCTURAL HIERARCHY DEVELOPED IN CO-INJECTION MOLDED POLYSTYRENE/ POLYPROPYLENE PARTS Kadota M; Cakmak M; Hamada H Akron,University; Kyoto,Institute of Technology The structural gradients developed in co-injection moulded PP/PS parts were investigated as a function of process history and injection sequence. A series of parts with PP skin/PS core, PS skin/PP core and PP skin/PP core was prepared under selected mould temps. and injection speeds and detailed structural analyses were performed using a series of techniques, including polarised light microscopy, birefringence, microbeamwide-angle X-ray diffraction(WAXD) and pole WAXD methods. 59 refs. JAPAN; USA

Accession no.719382 Item 188 Plastics Product Design and Development Forum. Retec. Chicago, Il., 31st May-2nd June 1998, paper 10. 115 CO-INJECTION MOULDING: CURRENT APPLICATIONS McRoskey J Co-Mack Technology Inc. (SPE,Product Design & Development Div.) Co-injection is one of many two-component processes available today. Unlike other multi-material moulding processes, the co-injection process is characterised by its ability to completely encapsulate an inner core resin with an outer skin material. This encapsulation of one resin by another provides product in which only one material is evident, unless the product is sectioned. A cross-section of a moulding shows a three-layer effect: skin, core and skin (which is why co-injection is sometimes referred to

68

as ‘sandwich moulding’). Co-injection process mechanics rely on the sequential injection of two different materials through the same gate(s), and usually with some amount of simultaneous injection. In general, a majority of skin material is injected into a cavity, followed by a combination of both skin and core materials flowing into the same cavity, and then followed by the balance of the core material to fill the cavity. Restated, the injection sequence is: skin, followed by skin and core concurrently, followed by core. Accurate sensors, sensitive electronics, and fast response valves permit excellent process repeatability. Proper shut-off and valving of the materials prevent cross contamination. Laminar polymer flow and cavity cooling promote well-defined and predictable boundary layers of the materials. USA

Accession no.719237 Item 189 Kunststoffe Plast Europe 89, No.1, Jan.1999, p.20-3; p.68/72 RELIABLE PROCESSING OF LIQUID SILICONE RUBBER (LSR) INTO TECHNICAL MOULDINGS Haberstroh E; Henze E; Ronnewinkel C In a number of research projects, the IKV is working intensively with raw material and machine manufacturers as well as the processing industry on technologies for processing LSR. These activities are concentrating on process analysis and process development for injection moulding. Aspects covered include control of the quality of the moulding, process sequences in the pvT diagram, fuzzy logic for control of moulding weight, function of the fuzzy controller, effect of the control system, simulation of the flow and curing behaviour, multicomponent injection moulding of LSR thermoplastic combinations, polyamide/LSR composites and production of LSR components with functional cavities using the gas injection technique. 9 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.719224 Item 190 Patent Number: EP 894604 A1 19990203 INJECTION MOULD FOR OVER-MOULDING ARTICLES AND AN INJECTION MOULDING MACHINE AND METHOD THEREFOR Sicilia R; Schad R; McGinley T; Hietkamp D; Catoen B; Gross K Husky Injection Molding Systems Ltd. The injection moulding machine comprises an array of one or more cores, which engage arrays of one or more first cavity and arrays of one or more composite cavities. Each composite cavity is formed from a combination of a second cavity and a cavity extension,

© Copyright 2002 Rapra Technology Limited

References and Abstracts

which carries at least a portion of a different geometrical profile, such as a thread. The cavity extension may comprise a pair of cavity portions, which are mounted adjacent the core to laterally movable slides on a movable plate, such as a stripper plate. During moulding of the first layer, the cavity extension elements are moved out of alignment with the first cavity and during moulding of the second layer the cavity extension elements are moved in to form a composite cavity with the second cavity so that only the second layer replicates the geometrical profile of the composite cavity. The cavity extension may be a single element, which is moved between a disengaged position wherein the core can be inserted into the first cavity and an engaged position wherein the core is inserted into the composite cavity. CANADA

Accession no.718531 Item 191 Modern Plastics International 29, No.2, Feb.1999, p.82 BLACK FOREST MOULD MAKER FOBOHA PIONEERS MULTI-COMPONENT MOULDS Smock D Multi-component mould making now constitutes close to 80% of the business at Foboha Formenbau. At the recent K Fair in Dusseldorf, the first-ever electrically actuated coinjection mould was demonstrated producing toothpaste tube shoulder components with an inner PETP barrier layer and an outer layer of PE. In another innovation, a multi-component mould featured a horizontal rotary platform instead of a vertical carousel previously used in the part. FOBOHA FORMENBAU GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.714503 Item 192 Modern Plastics International 29, No.2, Feb.1999, p.37-8 IN-MOULD ASSEMBLY MAKES DEBUT IN NORTH AMERICA Snyder M R Fickenscher America is applying the in-mould assembly process to make automotive air vents. The company’s inmould assembly technology was obtained in a technology transfer from its German partner, Fickenscher & Co. The technology is a multishot injection moulding process resembling progressive stamping, in which a finished part is ejected with each machine cycle. FICKENSCHER AMERICA CO. USA

Accession no.714489

© Copyright 2002 Rapra Technology Limited

Item 193 Polymer Composites 19, No.6, Dec.1998, p.738-46 INVESTIGATION OF THE ROLE OF TRANSVERSE FLOW IN CO-INJECTION RESIN TRANSFER MOULDING Gillio E F; Advani S G; Gillespie J W; Fink B K Delaware,University; US,Army Research Laboratory A co-injection resin transfer moulding (CIRTM) process was developed which enabled two or more resins to be simultaneously injected into a mould filled with a stationary fibre preform. The process allows for the manufacturing of co-cured multi-layer, multi-resin structures in a single processing step. A separation layer is used to provide resin compatibility during cure and to control resin mixing. Scaling issues relating to the role of transverse permeability in resin mixing were investigated. Two different approaches are presented which were taken to understand the causes of transverse flow and to quantify the amount of transverse flow that occurred during processing. 12 refs. USA

Accession no.711068 Item 194 Plastiques Flash Nos.304/5, March 1998, p.40-3 French TWO-MATERIAL MOULDING OF TOOTHBRUSHES An account is given of the activities of the La Brosse & Dupont Group of France in the two-material injection moulding of toothbrushes, generally from PP and thermoplastic elastomers. Moulds and machinery used in production are described, and turnover and employment figures are presented for the Group. LA BROSSE & DUPONT; GUILBERT; DSP; DKCODIM EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; WESTERN EUROPE

Accession no.710659 Item 195 Patent Number: US 5800751 A 19980901 METHOD OF MAKING PAINT BRUSH WITH CO-INJECTION MOLDED HANDLE Barker R L Wooster Brush Co. A paint brush handle has an outer layer of a comfortable, relatively soft elastomeric material which surrounds a rigid core of foamed polyolefin. The handle is made using a co-injection process in which a mould cavity is first coated by an initial partial shot of the elastomeric material and then filled by injecting more elastomeric material and polyolefin material containing a foaming agent simultaneously. The simultaneous shot of these materials

69

References and Abstracts

is achieved by injecting the materials through a single inlet passage into the mould cavity in which the flows are concentric, with the elastomeric material surrounding the polyolefin material. The ferrule is attached to the handle using nails or other suitable fasteners which penetrate into the rigid inner core.

of a bi-coloured keyboard) and is at present undergoing something of a renaissance. MANNESMANN; DEMAG PLASTICS MACHINERY; ICI EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; NORTH AMERICA; WESTERN EUROPE

USA

Accession no.706354

Accession no.710179 Item 196 Kunststoffe Plast Europe 85, No.11, Nov.1995, p.16-8 OPTIMIZED BONDING OF COMPOSITES IN OVER-INJECTION Costalas E; Krauss H DLR The process of over-injection as a manufacturing technique for thermoplastic components is discussed. Continuous fibre-reinforced thermoplastic base items or inserts are over-injected with short fibre injection grade material in a cost saving process for the manufacture of high strength and stiffness components of an arbitrarily complex form. By combining compression moulding with injection moulding, additional functions can be added to a continuous fibre-reinforced component. Particular attention is paid to the bonding mechanism between the two materials. 14 refs. DORNIER LUFTFAHRT GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.709863 Item 197 Kunststoffe Plast Europe 85, No.9, Sept.1995, p.20-1 ICE-COLD TRICK Jaroschek C Ferromatik Milacron GmbH Details are given of an inexpensive means of producing movable joints by an overmoulding technique. The multistage injection moulding method has the same material moulded on top of it. The technology is illustrated in the production of a lock hinge. 4 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.709844 Item 198 Popular Plastics and Packaging 43, No.10, Oct.1998, p.68-70 MULTI-COMPONENT INJECTION MOULDING REDISCOVERED This article discusses the process of multi-component or multi-colour injection moulding, a technique that was first developed some twenty years ago (with the production

70

Item 199 Revista de Plasticos Modernos 74, No.497, Nov.1997, p.465-72 Spanish MULTI-MATERIAL INJECTION MOULDING TECHNOLOGY Battenfeld GmbH The principles of two-material and multi-material injection moulding are examined, and machinery developed by Battenfeld for use in these processes is described. Processing parameters influencing adhesion between rigid and flexible materials in moulded components are discussed. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.706043 Item 200 European Rubber Journal 180, No.12, Dec.1998, p.17 ENGEL SEES MULTI-PART POTENTIAL White L Expertise in multi-component injection moulding gives Engel an edge in this rapidly expanding, high technology field. The company’s new E-S250V Elast injection moulding machine has run two-part test mouldings completely automatically. Engel sees great opportunities for all sorts of materials combinations, including hard/ soft plastic/rubber, plastic/TPE, plastic/liquid silicone rubber and rubber/rubber parts. ENGEL AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.705135 Item 201 Injection Moulding International 3, No.6, Oct./Nov.1998, p.52-4 MOULDS THAT WORK. XII. ADJUSTABLE VENTS IN THREE SHOTS An injection mould which produces an adjustable climate control vent via three-shot moulding is described. Design and construction are from Fickenscher of Germany, which is also the patent-holder and manufacturer of the part. The A climate control vent consists of a housing with louvres that can be rotated around their axis lengthwise. In addition, a linkage is connected to the louvres that

© Copyright 2002 Rapra Technology Limited

References and Abstracts

permits smooth, simultaneous adjustment of all louvers and thus directional control of the air flow. The vent is assembled from different thermoplastic materials in three mould stations by multi-shot/multi-component injection moulding. The plastics are selected largely on an empirical basis and, in addition to meeting a large number of specific requirements (gloss, scratch resistance and combustion characteristics), they must exhibit incompatibility in order to assure movement of the individual components. The three louvres are 20% glass microsphere-filled PBTP, the linkage is 20% talc-filled PP and the housing is modified PPO. Bonding of the components must be prevented under all circumstances. The smaller the surface areas in contact, the less likely is the risk of any initial melting. FICKENSCHER & CO.GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.704751 Item 202 Professional Engineering 11, No.20, 4th Nov.1998, p.43 SENSE AND SENSITIVITY Greek D In their quest to boost products’ consumer appeal and differentiate them from those of their rivals, many companies are now investigating combining more than one material. For example, a number of commercial high street products, such as toothbrushes, now boast soft grip handles or flexible areas. The basic products are made of the same hard PPs, but they are overlaid with soft grade thermoplastic elastomers. While this can be achieved through overlay moulding, a process called multi-shot moulding is increasingly being used. This means combining a maximum of three materials, but usually two, on a single product. Multi-shot technology is not new having been around for some 25 years, most notably for the automotive industry which uses it in the manufacture of vehicle tail-lights. However, the specialist tooling required has proved far too expensive for many manufacturers. The advantages and disadvantages of multi-shot moulding are examined. SCIENTIFIC GENERICS; SIFAM LTD.; ADVANCED ELASTOMER SYSTEMS LP EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.704484 Item 203 Plastics News(USA) 10, No.36, 19th Oct.1998, p.13 TEKNOR TPES GET A GRIP ON OVERMOULDED PARTS Esposito F Teknor Apex has introduced its new line of Tekbond thermoplastic elastomers. The materials, based on

© Copyright 2002 Rapra Technology Limited

styrenic block copolymers, are designed to be overmoulded directly onto most rigid thermoplastics for soft-touch grips and multi-component parts. The Tekbond line can be easily overmoulded onto dissimilar engineering plastics, such as polycarbonate and nylon. TEKNOR APEX CO. USA

Accession no.702619 Item 204 Plastiques Flash No.302, Nov./Dec.1997, p.100-3 French MULTI-COMPONENT INJECTION MOULDING: WHO WANTS WHAT? Results are presented of a survey undertaken by KraussMaffei among some 200 West European plastics processors to assess their interest in multi-material injection moulding and the criteria they would apply in selecting machinery for use in this process. Technical features of Krauss-Maffei’s Multinject multi-material injection presses are described. KRAUSS-MAFFEI AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE; WESTERN EUROPE-GENERAL

Accession no.702540 Item 205 Plastics Engineering 54, No.10, Oct.1998, p.27-31 OPPORTUNITIES FOR THE NEXT DECADE IN INJECTION MOULDING Schmidt L R Schmidt L.R.,Associates Developments in injection moulding technologies are reviewed and discussed, as the processing technology responds to developments in polymers, blends and material systems which require special enhanced processing features. Such material developments has resulted in grades of material which are more viscoelastic, and have been matched by advanced moulding technologies which have addressed the coupling of viscoelastic material responses with the process parameters. Moulding methods described include coinjection, gas assisted, low-pressure moulding, overmoulding, profiled injection rate, injectioncompression moulding, lost-core moulding, and computer aided engineering. It is argued that when the effect of pressure on viscosity and transient melt behaviour are properly accounted for in the process setup, many new opportunities will be realised and successfully commercialised. 15 refs. USA

Accession no.701329

71

References and Abstracts

Item 206 European Plastics News 25, No.10, Nov.1998, p.43 SOFT SELL Beevers A Scientific Generics, Advanced Elastomer Systems and Sifam recently linked up to demonstrate the full potential of using thermoplastic elastomers in multi-shot mouldings. The three companies developed a new design for a computer mouse which comprises a soft-touch layer over the main body and both of the buttons. Talc-filled PP and Santoprene 8000 TPE were used for the part. ADVANCED ELASTOMER SYSTEMS; SIFAM LTD.; SCIENTIFIC GENERICS EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.700558 Item 207 Molding Systems 56, No.7, Sept.1998, p.9 GET A GRIP Warner Tools can now offer a soft-touch grip on its ProGrip paint scrapers. Designers selected Sarlink 3460 thermoplastic elastomer from DSM Thermoplastic Elastomers for the soft grip component. The part is moulded using a two-shot insert-moulding process with two horizontal 88-ton injection presses. Another elastomer product for injection moulding is Alcryn from Advanced Polymer Alloys. DSM THERMOPLASTIC ELASTOMERS INC.; ADVANCED POLYMER ALLOYS USA

Accession no.700077 Item 208 Plastics Technology 44, No.11, Oct.1998, p.42-6 TAKE A SHOT AT MULTI-COMPONENT MOULDING Ogando J When seeking a way to cut part costs or add value to moulded components, the route to achieving both goals for more and more moulders is multi-component moulding. A collection of several different techniques, multi-component moulding offers the ability to combine different materials or colours in a single one-shot or multi-shot process. Multi-shot processes such as overmoulding can drive down part costs by squeezing what would otherwise have been two distinct moulding jobs plus an assembly operation into a single manufacturing step. The cost reduction can be as great as 25-50%. Overmoulding can also add value by making the end product more attractive to consumers through the addition of splashy colours or soft-touch elastomeric materials. Similar benefits of cost reduction and added

72

functionality can be achieved with mono-sandwich moulding and coinjection, two methods that combine different melt streams in a single shot. The most popular application of these single-shot methods is to ‘bury’ regrind or less costly materials under an outer skin that must meet strict aesthetic or functional requirements. The savings can be as much as 50%, according to Cincinnati Milacron. These single-shot methods can just as easily insert special functional layers under the outer skin - such as a foamed core underneath a solid skin or a coinjected barrier layer within a PETP bottle preform. Details are given. GW PLASTICS; CINCINNATI MILACRON INC USA

Accession no.699972 Item 209 Kunststoffe Plast Europe 88, No.9, Sept.1998, p.22-3,1412/6 German; English HORIZONTAL MOULD ROTATION. MULTICOMPONENT INJECTION MOULDING MADE EVEN MORE ECONOMICAL BY A MULTIDAYLIGHT TECHNIQUE Jaroschek C; Steger R Bielefeld,Fachhochschule; Ferromatik Milacron Maschinenbau GmbH The development of a multidaylight mould with a rotating centre plate is described, with particular reference to improvement of the economy of the overmoulding process. The main advantage of the multidaylight principle is shown to be the reduction of clamping forces and of production costs. An example of a car rear light is given in which a reduction of 15% is achieved in machinerelated production costs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.699033 Item 210 Kunststoffe Plast Europe 88, No.9, Sept.1998, p.22,p.1408/10 German; English FAST DEMOULDING. COLLAPSIBLE CORES FOR MULTI-COMPONENT TECHNOLOGY Bourdon R; Kasparbauer K Rodinger Kunststoff-Technik GmbH Multi-component injection moulding requires spacesaving tools in order to be able to produce on smaller machines and more economically. It is shown that, with the aid of special collapsible core technology, even circumferential undercuts can be demoulded with a demoulding stroke of just 4.5 mm. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.699032

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Item 211 Plastiques Flash Nos.294/5, Jan./Feb.1997, p.70-4 French GETTING TO KNOW TWO-MATERIAL INJECTION MOULDING An account is given of topics discussed at a seminar on two-material injection moulding held in November 1996 by Polymix of France. These include the production of components combining thermoplastics and Thermolast K styrene-ethylene butylene-styrene block copolymer thermoplastic elastomers (Kraiburg), Hercule MultiInjection presses developed by Billion for use in this process, moulds produced by Grosfilley, and some product developments by General Plastics. POLYMIX; KRAIBURG; GUMMIWERK KRAIBURG GMBH; BILLION SA; GROSFILLEY; GENERAL PLASTICS SA; SHELL CHEMICAL CO. EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; GERMANY; USA; WESTERN EUROPE

Accession no.698923 Item 212 European Plastics News 25, No.9, Oct.1998, p.101-4 MULTI-COMPONENT MOULDING The wide variety of technology options available for multi-component injection moulding are outlined. Arburg’s Allrounder 320S, which is available as a twocomponent machine in clamping forces of 35 and 50 tonnes, has six different combinations of injection unit sizes. Ferromatik Milacron will be demonstrating the production of toothpaste tube shoulders using its overmoulding process. Advances in coinjection and overmoulding technologies are being used to produce multilayer PETP preforms which incorporate higher levels of recycled material or advanced barrier materials. USA; WESTERN EUROPE-GENERAL

Accession no.698891 Item 213 Injection Molding 6, No.8, Aug. 1998, p.89-90 BACKFLOW REVISITED: THE STREAK IN THE RUNNER Sloan J Statements questioning the existence of the backflow phenomenon are challenged by Klay Schulz of Phillips Plastics. He cites the example of an automotive lightswitch cover, moulded in two shots in a two-material process. The first shot consists of a black ABS overmoulded by a clear acrylic. Proof of backflow is presented in the form of the acrylic runner which had a streak of black ABS running through the centre of it. Efforts to solve the problem by alterations in holding time are reported.

© Copyright 2002 Rapra Technology Limited

PHILLIPS PLASTICS USA

Accession no.693219 Item 214 Antec ’98. Volume III. Conference proceedings. Atlanta, Ga., 26th-30th April 1998, p.2618-22. 012 COINJECTION MOULDING OF THERMOPLASTICS REINFORCED WITH PREGENERATED TLDP FIBRILS McLeod M A; Baird D G Virginia,Polytechnic Institute & State University (SPE) Thermotropic liquid crystalline polymer (TLCP) fibrils of higher melt processing temperature are generated within PETP of lower melt processing temperature using a novel mixing technique. The strands exiting the mixing system are compressed into cartridges and then coinjection moulded to form plaques. In comparison to conventionally injection moulded pregenerated microcomposites, coinjection moulded composites have higher flexural moduli. The effect of the core material used to produce these composites is also investigated. 19 refs. USA

Accession no.692794 Item 215 Injection Molding 6, No.7, July 1998, p.78/80 TWO-COMPONENT MOULDING ON ONECOMPONENT MACHINE Kirkland C Coinjection (sandwich) moulding can now be performed on standard single-barrelled injection moulding machines. Addmix has developed a remarkably uncomplicated and affordable processing system called ‘sequenced screw loading’ to accomplish just that. The system feeds compatible materials through the injection unit’s feed throat in a predetermined computer-controlled sequence that is maintained as the materials travel through the shooter. The first material entering the cavity forms the aesthetically pleasing skin of the component and the second fills out the core. Any of the small degree of mixing of the two materials that might occur is buried in the core. Details are given. ADDMIX LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.692631 Item 216 Injection Molding 6, No.5, May 1998, p.127 COINJECTION MACHINE BROADENS ITS CAPABILITIES

73

References and Abstracts

The versatile new co-injection moulding machine from Cincinnati Milacron, the Magna, is highlighted in this article. Full details of its features and capabilities are provided. CINCINNATI MILACRON

outline of the advantages it offers product designers including reduced cycle times and decreased costs. ADDMIX LTD.

USA

EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.691773

Accession no.684129

Item 217 Plastics and Rubber Weekly No.1749, 14th Aug.1998, p.9 DUPONT APPLIES ADDMIX SYSTEM TO ETPS

Item 220 Antec ’98. Volume I. Conference proceedings. Atlanta, Ga., 26th-30th April 1998, p.372-6. 012 MONOSANDWICH INJECTION MOULDING: SKIN-CORE-STRUCTURE AND PROPERTIES OF SANDWICH MOULDED ANTIELECTROSTATIC COMPONENTS Kuhmann K; Ehrenstein G W Erlangen-Nurnberg,University (SPE) The sandwich injection moulding process leads to a nearly symmetric skin-core structure, consisting of the two outer skin layers and the inner core layer. Usually the skin material is injected with one injection unit followed by injecting the core material with a second injection unit. The mono-sandwich injection moulding process is a new sandwich moulding technique using only one injection unit for injecting both skin and core material in one step. The influence of mono-sandwich injection parameters and part geometry is experimentally analysed using a conductive filled polyethersulphone (PES) as skin material and unfilled PES as core material. The aim for using this material combination is to establish hightemperature resistant thermoplastic parts with an antielectrostatic surface suitable for application in the production of electronic parts. 6 refs.

DuPont Engineering Polymers claims to have proved the application of the Addmix processing technology with its crystalline engineering thermoplastics materials. Addmix is a novel injection moulding technique that allows sandwich moulded components to be produced on conventional single barrel moulding machines. The centre has now taken two projects through the early proving stages: an automotive fuel system part with a core of Delrin acetal and a skin of conductive Delrin; and an automotive engine cover manufactured in Zytel PA6 with a skin of the same polymer loaded with a metallic pigment. DUPONT ENGINEERING POLYMERS EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.688796 Item 218 Revue Generale des Caoutchoucs et Plastiques No.759, May 1997, p.31-3 French COMEBACK OF MULTI-COMPONENT INJECTION MOULDING Trocherie I; Posch W PCD; PCD Polymere An examination is made of the two-material injection moulding process as a means for producing components combining skins and cores of different materials, i.e. reinforced skins and non-reinforced cores and vice versa, flexible skins and rigid cores and vice versa, and nonreinforced skins and filled cores with barrier properties. The influence of viscosity ratios on thickness distributions is discussed for the case of components having skins and cores made of PP resins of different molecular weight. EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; GERMANY; WESTERN EUROPE

Accession no.686295 Item 219 Medical Device Technology 9, No.6, July/Aug.1998, p.38-9 SANDWICH MOULDING USING SEQUENCED SCREW LOADING It is explained that sequenced screw loading is an alternative method for injection moulding two materials. This article explains the process, and then provides an

74

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.683976 Item 221 Antec ’98. Volume I. Conference proceedings. Atlanta, Ga., 26th-30th April 1998, p.351-7. 012 SEQUENTIAL COINJECTION HOT RUNNER Moss M D Kona Corp. (SPE) Coinjection moulding for large automotive applications is gaining acceptance. The use of regrind as the core material is an important driver of the technology. In recent years, sequential filling using valve gates has also become an important technology for the moulding of bumper fascia and other parts. Sequential filling is used to improve control of part filling and control weld lines. Hot runner systems have been developed which combine both sequential filling and coinjection moulding technologies. A description of the process is given, discussing important hot runner design issues. 2 refs. USA

Accession no.683972

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Item 222 Molding Systems 56, No.5, May/June 1998, p.41-3 MULTI-SHOT PROCESS IS A TEAM EFFORT The new one-time Fun Saver sport camera, with its onehanded operation and rubberised waterproof casing, was the most complex multi-shot injection moulding project ever attempted by Kodak. The company partnered injection moulding machine maker Ferromatik Milacron and mouldmaker Foboha to develop a process for moulding the hard inner housing of clear PS overmoulded with a soft, coloured outer layer. KODAK; FERROMATIK MILACRON GMBH; FOBOHA EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; USA; WESTERN EUROPE

Accession no.682398 Item 223 Plastiques Flash No.296, March 1997, p.56-7 French INTERNAL HEATING: AN EFFECTIVE SOLUTION IN MULTIPLE INJECTION MOULDING Hot runner injection mould systems developed by Ewikon are examined, and the advantages of internal heating in two-material injection moulding are discussed with reference to the manufacture of automotive and medical components combining a rigid thermoplastic and a flexible elastomer. EWIKON HEISSKANALSYSTEME EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.682340 Item 224 Plast’ 21 No.58, Jan./Feb.1997, p.61-2 Spanish MULTI-COMPONENT INJECTION MOULDING Linazisoro I Developments by Battenfeld in machinery and control systems for two-material and multi-material injection moulding are reviewed. BATTENFELD GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.682321 Item 225 Patent Number: EP 842750 A1 19980520 PROCESS FOR PRODUCING ARTIFICIAL MARBLE HAVING STRIPED PATTERN Mukai N; Shibazaki M

© Copyright 2002 Rapra Technology Limited

DuPont-MRC Co.Ltd. Liquid resins, each having a different colour, are laminated by injection in a moulding cell so that at least two layers are formed. A comb-like tool is moved in the laminated liquid resins while the blades thereof are contacted with the bottom surface of the moulding cell. The liquid resins are then cured to produce artificial marble having a striped pattern, which is clear and formed continuously along the thickness direction and does not disappear when the surface of the marble is ground. JAPAN

Accession no.682232 Item 226 Macplas International May 1998, p.43 DUAL INJECTION MIR recently displayed a 1100-ton press designed for comoulding different materials and/or colours. During the trials, a toilet seat was moulded using PP filled with wood flour inside and ABS for the external skin. Bodini Presse has developed the Enysave 2GL range of injection machines for two-material moulding. The Roto HSSP BIC/8 model introduced by Presma is an eight-station rotary moulding machine suitable for producing eight items different in weight and size. EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.681936 Item 227 Plastics and Rubber Weekly No.1741, 19th June 1998, p.15 FM NEW TWO-SHOT MOULDING IDEAS Ferromatik Milacron has unveiled two developments in the two-component moulding process, both designed to cut entry level to this cost effective manufacturing technology. The company has developed a mould design that rotates the cavities between the platens, rather than on the platen, in what can best be described as a specialised stack mould. In a second development, FM has devised a new variant on its Mono-Sandwich technology that allows overmoulded parts to be produced using just one injection unit with a simple secondary extruder. FERROMATIK MILACRON GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.681928 Item 228 Injection Molding 6, No.2, Feb.1998, p.81-3 MANUFACTURING - AVOIDING ASSEMBLY COSTS BY LETTING THE MOLD DO IT Witzler S

75

References and Abstracts

This article examines the process of in-mould assembly a multi-shot injection moulding process resembling progressive stamping, where the first shot produces the preform and the second (or third, or fourth, or fifth) produces the finished product. The technology has been developed by Fickenscher & Co. GmbH of Germany. Full details are provided. FICKENSCHER & CO.GMBH; FICKENSCHER AMERICA EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; USA; WESTERN EUROPE

Accession no.677283 Item 229 European Plastics News 25, No.4, April 1998, p.21/3 PHOTO SYNTHESIS When Kodak’s production site in the US wanted to manufacture its new single-use camera, it decided to use multi-component moulding. Kodak chose injection moulding machinery maker Ferromatik Milacron and mouldmaker Foboha as its partners in the project. The camera case features a hard inner housing of clear PS, overmoulded with a rubbery outer coloured layer. This outer layer provides a grippable and shock-absorbing cover and also acts as an integral waterproof seal. KODAK; FERROMATIK MILACRON GMBH; FOBOHA EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; USA; WESTERN EUROPE

Accession no.677014 Item 230 Popular Plastics and Packaging 42, No.11, Nov.1997, p.59/62 OPPORTUNITIES FOR INJECTION MOULDED COMPONENTS IN THE AUTOMOBILE INDUSTRY Kumar K N LTM Ltd. This article investigates the opportunities for injection moulding components for the car industry, and considers: current trends in the use of plastics in cars (exterior components, interior components, under-the-bonnet components), innovative manufacturing techniques (mould surface decoration, cascade injection moulding, gas injection process, lost core moulding, two-polymer injection moulding), and machine selection (specifications, controls and hydraulics, and quality control features). EUROPE-GENERAL; INDIA; JAPAN

Accession no.676903 Item 231 Plastics Southern Africa 27, No.8, Feb.1998, p.14/20

76

MULTILAYER PREFORMS Bichler M; Klotz B Mannesmann Demag Production methods are described for a multilayer preform which includes a core layer of recycled PETP, manufactured using the coinjection process. Production systems with highly developed machine, mould and process engineering are demonstrated which ensure the optimum economic results. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.676222 Item 232 Plastics News(USA) 9, No.50, 9th Feb.1998, p.10 LOST-CORE PARTS CRUX OF CORETECH EXPANSION Pryweller J CoreTech Associates has opened a 6,000 sq.ft. plant in Grand Rapids, Michigan, to make lost-core plastic parts. The facility, which opened in January 1998, will use lost-core moulding to make parts for the aerospace and recreational-goods industries and for other general industrial applications. The process, used extensively to make air-intake manifolds for vehicles, can translate well to other applications. The technology involves injection moulding a part around a cast metal core and then melting the core in a chemical bath. CoreTech plans to use its metal core technology for such applications as pump housings, dental devices and thrust reversers on jets. Future applications could also include boat paddles or oars, golf balls and musical instruments. Details are given. CORETECH ASSOCIATES INC.; CORETECH COMPOSITE PRODUCTS INC. USA

Accession no.676143 Item 233 Injection Molding 6, No.4, April 1998, p.158 MULTIMATERIAL ROTARY TWO-PLATEN MACHINES The design and construction is described in some detail of Husky Injection Molding Systems’s two-platen large tonnage line, which has been expanded to include a full range of multi-material rotary platen machines. The rotary platen is available on machines from 825 to 1800 tonnes, and uses a standard two-platen design with the addition of a servodriven rotary turntable and up to four injection units. HUSKY INJECTION MOLDING SYSTEMS INC. USA

Accession no.675534

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Item 234 Plastics and Rubber Asia 13, No.77, March 1998, p.32 TEXTILE OVERMOULDING FROM BATTENFELD Battenfeld has developed an overmoulding application on a BA 2700/1900 HM unit which shows how the benefits of this technology can be economically exploited using an application-specific combination of injection moulding machine, mould textile and automation. The increasing use of the overmoulding of films and textiles is being driven by the automotive industry, according to Battenfeld. Brief details are given of the moulding process. BATTENFELD AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

industry, forced by foreign competition during the 1980s, has also led the way in providing an emphasis toward improved part quality resulting in longer part life cycles. In addition, automotive producers are shortening their design engineering phase which has caused the plastics industry to find methods to more rapidly move technology from research and development to end-use applications. Some new process techniques are reviewed that are answering the demand of the automotive plastics industry for lower cost and faster time to market. These include pulsed cooling and induction heating for mould temperature control, multi-live feed moulding, lamellar injection moulding, injection-compression moulding, lost core moulding, the Maus-Galic process and pressurised sealed cavity injection moulding. 13 refs. USA

Accession no.675293

Accession no.674858

Item 235 Medical Device Technology 9, No.3, April 1998, p.26-8 MULTI-SHOT INJECTION MOULDING Tinson J Sifam Ltd.

Item 237 Kunststoffe Plast Europe 88, No.2, Feb.1998, p.23 RIGID AND FLEXIBLE ALTERNATELY Komander J Schulman A.,GmbH

Medical device manufacturers are beginning to combine multi-colour and multi-material moulding techniques with soft touch materials to gain competitive advantage. This trend is driven by the availability of machines that can injects as many as six different materials simultaneously. The multi-shot moulding process is examined, using examples to highlight the benefits of the technique.

The advantages afforded by the use of coinjection moulding methods with respect to production costs and assembly are discussed, with reference to the manufacture of a motion sensor by Merton GmbH. The application used adhesion-modified SEBS as the flexible component together with ASA as housing material for the motion sensor. The flexible component has the function of sealing with respect to the top part of the housing, and also acts as a gland for cable passages. MERTEN GMBH

EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.675071 Item 236 New Plastics Applications for the Automotive Industry. Conference proceedings. Warrendale, PA, Society of Automotive Engineers, 1997, p.131-9. 63 Tr.Ro WHAT’S NEW IN PLASTICS INJECTION MOULDING PROCESSES FOR AUTOMOTIVE APPLICATIONS: AN UPDATE Grelle P F; Derouac K A Dow Plastics (Society of Automotive Engineers) Over the last ten years, the plastics industry has been under pressure by many industries, such as automotive, to resolve issues from an application point of view, such as value engineering, part quality and time to market. Value engineering programmes have been a major thrust for the last several years in many industries. These programmes have taken the form of low cost materials, systems integration, part weight reduction and lower fabrication costs. The automotive

© Copyright 2002 Rapra Technology Limited

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.671869 Item 238 Materie Plastiche ed Elastomeri No.9, Sept.1996, p.494-6 Italian ADVANTAGES OF DUAL INJECTION MOULDING Baucia G The RPM range of dual injection and coinjection moulding machines developed by MIR is reviewed. Some applications of these machines in the processing of plastics and thermoplastic elastomers are described, and their advantages in terms of reduced energy consumption and increased productivity are discussed. MIR SPA EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.670840

77

References and Abstracts

Item 239 Molding Systems 56, No.1, Jan.1998, p.30-5 CHOOSING A MULTI-MATERIAL MOULDING PROCESS Tolinski M Coinjection moulding, encapsulating one polymer within another, allows the use of less costly material, even regrind, inside the part. Engineered applications use the core material to provide structural strength, while the outer skin can be a softer material. Process equipment options for coinjection and multi-shot moulding are discussed. USA

Accession no.669119 Item 240 Molding Systems 56, No.1, Jan.1998, p.16-9 AUTO INDUSTRY LEADS THE PACK Strohmaier F Engel North America To meet the demands of their automotive customers, North American injection moulding equipment manufacturers, materials suppliers and moulders have developed a number of innovative multi-component processes. This article discusses multi-colour and multi-material moulding, in-mould operations such as in-mould assembly, in-mould painting, in-mould labelling and inmould lamination, and coinjection moulding. USA

Accession no.669116 Item 241 Plastics and Rubber Weekly No.1725, 27th Feb.1998, p.11 AUTOMOTIVE DRIVES MULTI-SHOT ORDERS Interest in multi-shot moulding has never been higher than it is today, claims Engel. Each year the company supplies around 300 machines with two or more injection units and the clamp tonnages are ever increasing. It is the development of TPEs and the ability to make hard/soft combinations that is driving the process today. ENGEL UK LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.668963 Item 242 Modern Plastics International 28, No.2, Feb.1998, p.30-1 COINJECTED BUMPER FASCIA IS A RECYCLING SUCCESS STORY Grande J A Ford Motor has affirmed the viability of coinjection moulding in large automotive applications by introducing

78

the first coinjected bumper fascia in North America. The fascia utilises virgin thermoplastic olefin elastomer (TPO) for the skin and painted, plant-generated TPO scrap for the core. The 4kg fascia consists of 23% core material and materials cost savings are estimated at 1.50-1.80 US dollars per finished part. FORD MOTOR CO. USA

Accession no.668128 Item 243 Patent Number: EP 823323 A1 19980211 COINJECTION METHOD FOR PLASTIC COMPONENTS, PARTICULARLY FOR SHOES Sandri A; Bacchetto M Benetton Sportsystem SpA This involves a first injection in a mould of a first material in an amount between 60 and 80% of the total weight of the component to form the outside walls of the component. This is followed immediately by a second injection of a second material, which is chemically compatible with the first material and has similar rheological properties in an amount between 40 and 20% of the total weight of the component. The second material forms the inner layer, which is contained within the walls of the component, and is injected at a region of the component, which is subjected to stresses during use. EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.667928 Item 244 Materie Plastiche ed Elastomeri No.6, June 1996, p.368-70 Italian HEAVYWEIGHT AMONG ROTARY PRESSES Baucia G Details are given of the Roto System BIC 10000/600/5 five-station rotary injection press developed by Presma of Italy for the production of garden furniture. The use of this machine in coinjection moulding sandwich structures consisting of virgin and reclaimed PP is described. PRESMA SRL EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.666961 Item 245 European Rubber Journal 180, No.2, Feb.1998, p.27-8 CABLE JOINT USES NEW APPROACH White L ABB Kabeldon has developed an injection moulded EPDM part for joining medium-voltage cables. The jointing unit, called the SlipOver, comprises a three-layer

© Copyright 2002 Rapra Technology Limited

References and Abstracts

tubular “sausage” made of insulating EPDM rubber sandwiched between layers of conductive EPDM. Production is completely automated and uses an innovative three-layer injection moulding process. ABB KABELDON AB SCANDINAVIA; SWEDEN; WESTERN EUROPE

Accession no.666334 Item 246 Patent Number: EP 816066 A2 19980107 PAINTED PLASTICS ARTICLES Easterlow R A; Coates R J; Smith G F; Stidworthy P D Rover Group Ltd. A vehicle wing comprises a PP substrate coated with a polyamide coating, which makes the wing suitable for subsequent painting on a normal vehicle paint line used to paint a metal body in white. To promote adhesion between the PP substrate and the polyamide coating, the substrate includes an admixture of a compatibiliser, such as a maleic anhydride grafted PP. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.664305 Item 247 Plastiques Modernes et Elastomeres 47, No.10, Dec.1995, p.71-3 French INJECTION MOULDING CHANGES ITS STANDARDS Topuz B A number of non-standard plastics injection moulding processes and associated machinery developments are examined. Processes discussed include gas, two-material, multi-material, multi-colour and fusible core injection moulding and insert moulding. BILLION SA; REYDEL SA; PLASTIC OMNIUM SA; FORD MOTOR CO.; CINPRES LTD.; GENERAL MOTORS CORP.; PRODAIR; BAUER COMPRESSORS GMBH; HYDAC; BATTENFELD GMBH; HUSKY INJECTION MOULDING SYSTEMS LTD.; KRAUSS-MAFFEI AG; STMP; MANNESMANN DEMAG; PRESSES KAP; MECAPLAST; MGI-COUTIER; OZEN CANADA; EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; GERMANY; UK; USA; WESTERN EUROPE

Accession no.663455 Item 248 International Polymer Processing 12, No,3, Sept.1997, p.216-27 NUMERICAL SIMULATION OF THE MULTICOMPONENT INJECTION MOULDING PROCESS Zoetelief W F; Peters G W M; Meijer H E H Eindhoven,University of Technology

© Copyright 2002 Rapra Technology Limited

Multi-component injection moulding(MCIM) was studied with emphasis on the use of numerical tools for calculating the positions of material particles during the flow in the mould cavity. These tools made it possible to solve the inverse problem of predicting the injection sequence in MCIM given a required material distribution in the product. The simulations were validated using experimental results of a co-injected strip with stiffener ribs. The effect of a bifurcation of the midsurface on the material distribution was investigated numerically using a simplified model based on the local mass balance. 39 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; NETHERLANDS; WESTERN EUROPE

Accession no.663010 Item 249 Macplas International May 1997, p.87-8 MULTIPLE INJECTION Multiple injection presses from MIR are described. The company specialises in providing modular systems of standard units which provide adequate solutions for specific processing problems. MIR’s machines are claimed to provide energy efficiency with high productivity; allow for the production of parts with large surface areas using a lower clamping force than normally necessary; production by sandwich moulding; and simultaneous production of identical parts with different colours or materials. MIR SPA EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; WESTERN EUROPE

Accession no.662629 Item 250 Injection Molding 5, No.11, Nov.1997, p.98/105 TROUBLESHOOTER. XVIII. DIMPLES IN OVERMOULDED TPR Hatch R Prime Alliance The problem of dimples appearing at the gates of a glassfilled PP roller overmoulded with a thermoplastic elastomer material is described. Both moulds are eightcavity and each has a balanced runner feeding material into the cavities. The troubleshooting process employed to solve the problem is outlined. USA

Accession no.661823 Item 251 Kunststoffe Plast Europe 87, No.11, Nov. 1997, p.21-8 SPECIAL INJECTION MOULDING METHODS Rothe J

79

References and Abstracts

Esslingen,Fachhochschule fuer Technik All known variations of the injection moulding process are summarised and logically arranged and advantages and disadvantages as well as the necessary production equipment are described and evaluated. Techniques described include thermoplastic structural foam moulding; injection compression; sequential injection moulding; push-pull (counterflow) injection moulding; methods of combining several components (overmoulding of inserts, insert moulding and lost core moulding); outsert moulding; in-mould lamination, including in-mould labelling, in-mould decoration, and in-mould lamination of fabric; multi-component injection moulding; and multishot injection moulding. 33 refs.

Item 254 Plastics and Rubber Weekly No.1698, 8th Aug.1997, p.8 ENGEL INVESTS FOR ROBOT GROWTH A DM35m investment by Engel in a new robot manufacturing plant at Steyr in Austria, which will double the size of its existing operation, marks the beginning of a major expansion into the mainstream automation markets. The company’s goal is to be building 1000 servo robots a year in five years time. Engel is currently installing a number of robots at Siemens Automotive Systems in Telford to automate a manufacturing cell for lost core production of automotive inlet manifolds. ENGEL AUTOMATISIERUNGSTECHNIK GMBH

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

AUSTRIA; EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.660879

Accession no.645789

Item 252 Plastics World 55, No.10, Oct.1997, p.9-10 CO-INJECTION IS THE FUTURE FOR MOST PARTS: BEMIS Smock D

Item 255 Plastics News International July 1997, p.32-3 OPTIONAL TECHNIQUES AVAILABLE FOR MULTI-COMPONENT MOULDING

In the coinjection moulding process, two different materials fed from separate barrels are joined in a manifold so that one material can be encapsulated within the other. The process allows the use of regrind as an inner material, saving material costs, or can provide a synergistic combination of materials. Bemis Manufacturing claims impact resistance of some materials improves as much as two or three times when used in a coinjected structure. Bemis currently operates four 725-ton coinjection presses with machine manifold and in-mould manifold systems. BEMIS MANUFACTURING CO. USA

Accession no.654674 Item 253 Plastiques Modernes et Elastomeres 49, No.1, Jan./Feb.1997, p.37-8 French TWO-MATERIAL INJECTION MOULDING Gailliez E Some developments in materials and machinery for twomaterial and two-colour injection moulding are reviewed. These include Thermolast K styrene-ethylene butylene-styrene block copolymer thermoplastic elastomer compounds, developed by Gummiwerk Kraiburg for moulding in combination with rigid plastics, an injection press developed by Billion, and moulds produced by Grosfilley. POLYMIX; PLAYMOBIL; GUMMIWERK KRAIBURG GMBH; BILLION SA; GROSFILLEY EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; GERMANY; WESTERN EUROPE

Accession no.653046

80

Several similar but distinct injection moulding processes are available to integrate different materials and/or components into a single part. In its broadest sense, multicomponent moulding can be used for such applications as in-mould decoration (with coloured film, foil, screenprinted sheet, etc), insert moulding (as with steel blades in screwdrivers), hard/soft combinations (typically capitalising on the tactile attribute of TPE in the handles of various products), and two colour moulding (e.g. amber/ clear tall light lenses). These applications are increasing due to the technology’s ability to deliver substantial cost savings. Companies prepared to utilise this technology are achieving initial savings from the direct integration in the moulding process of what would otherwise be separate downstream operations such as printing, painting, welding, bonding and assembling individual components. Savings are also derived in some instances from the reduction of material costs, such as where it is possible to mould a part in a sandwich construction having a core of regrind or foamed material. Details are given. NETSTAL AG SWITZERLAND; WESTERN EUROPE

Accession no.645297 Item 256 Modern Plastics International 27, No.7, July 1997, p.21-2 LOST-CORE PROCESS EXPANDS IN NONAUTOMOTIVE ROLES Mapleston P M-Tec has shown via computer simulation how lost-core injection moulding can produce a multi-component assembly, in this case, an all-plastics gear box for a

© Copyright 2002 Rapra Technology Limited

References and Abstracts

motorised garage door assembly. Injection moulded gear wheels and shafts are located in a mould cavity of the same dimensions as the interior of the gear box. The lowmelting-point metal alloy is injected around the gear wheel assembly. That composite moulding is then used as an insert in a further mould used to produce the casing of the gear box, and then the metal is melted out. M-TEC; ELECTROVERT EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; USA; WESTERN EUROPE

Accession no.641172 Item 257 Antec 97. Volume III. Conference proceedings. Toronto, 27th April-2nd May 1997, p.2782-8. 012 MULTI-GATE CO-INJECTION HOT RUNNER Moss M D Dynisco Inc. (SPE) Co-injection technology for injection moulding is not new. Multi-layer parts have been in production for a few years. In the plastic bottle market, multi-cavity moulding of multilayer preforms is an active area. Also, there are several applications where single cavity, single gate parts are being produced. An example is the manufacture of toilet seats. In this case, transporting two different melt streams to the part is accomplished through a co-injection head mounted to twin injection barrels of a coinjection machine. Gating is usually through a long cold sprue to the part. However, up until recently there has been no successful application involving the use of a hot runner system to transport the melt to a multi-gate, single-cavity part such as an automotive bumper. This involves some special considerations of part analysis, process control, and hot runner manifold design. Some basic co-injection concepts are reviewed, and these special considerations are discussed using a Ford co-injected bumper fascia to illustrate. USA

Accession no.640416 Item 258 British Plastics and Rubber May 1997, p.28 SEQUENTIAL FEEDING PRODUCES “SINGLEBARREL CO-INJECTION” The two component injection moulding nozzle device introduced by AddMix at K’95 has been augmented by a feeding system able to cope with a more comprehensive range of materials. The nozzle converts a single barrel machine into a coinjection machine by selectively dosing the first part of the shot, which becomes the skin of the component. AddMix has introduced what it calls sequenced screw loading, which uses granular materials. Material is dosed to the screw in two parts which travel in sequence to the point of injection, and again form the skin in one material and core in the other.

© Copyright 2002 Rapra Technology Limited

ADDMIX EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.638731 Item 259 British Plastics and Rubber May 1997, p.26-7 MULTI-STATION MACHINES OFFER COST BENEFITS FOR CO-INJECTION The advantages of coinjection, or sandwich moulding, are outlined. Many of the machines on the market are derived from conventional high pressure single station injection moulding machines, but Presma has adopted a rotary design, with the moulds mounted on a carousel and being presented in turn to the injection units. Examples of high volume products (toilet seats and garden furniture) produced by the multi-station configuration are described. PRESMA CORP. USA

Accession no.638730 Item 260 Plastics and Rubber Weekly No.1692, 27th June 1997, p.14-5 MULTI COMPONENT MOULDING HAS “ENORMOUS POTENTIAL” Demonstrations held at Mannesmann Demag’s Wiehe plant recently included multi-component moulding, processing solid silicone rubber and microshot production in polycarbonate. The company claims hard/soft applications are one of the fastest areas of growth in multicomponent technology. Drives of Ergotech machines for MC moulding have been upgraded and now feature a multiple pump enabling all functions of both injection units to be run simultaneously. Four machine configurations are offered. MANNESMANN DEMAG AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.638660 Item 261 Modern Plastics International 27, No.6, June 1997, p.60-3 DESIGN FLEXIBILITY SPURS MOLDING OF MULTICOMPONENT PARTS Snyder M R The design flexibility afforded by the use of multicomponent and multi-colour moulding techniques are reviewed, and examples of applications in a variety of end-use applications are given. Advances in mould design are discussed. NORTH AMERICA; WESTERN EUROPE-GENERAL

Accession no.638009

81

References and Abstracts

Item 262 Patent Number: WO 9601732 A1 19960125 COINJECTED AUTOMOBILE BUMPERS Denison B R D & S Plastics International These are formed by coinjection moulding of a first thermoplastic material having good appearance and strength and a second thermoplastic material having appearance and/ or strength properties significantly inferior to those of the first thermoplastic material. The second thermoplastic material generally forms a core, which is entirely surrounded by a skin consisting of the first thermoplastic material, although in some instances a portion of the finished article, which will not be visible in use or has a special function, may be constituted by the exposed core material. USA

Accession no.637151 Item 263 Antec 97. Volume I. Conference proceedings. Toronto, 27th April-2nd May 1997, p.451-5. 012 INFLUENCE OF FLOW CONDITIONS AND INJECTION PARAMETERS ON BOND STRENGTH OF COMPATIBLE MATERIAL COMBINATIONS Kuhmann K; Ehrenstein G W Lehrstuhl fuer Kunststofftechnik (SPE) In multi-component injection moulding of rigid/rigid and rigid/flexible thermoplastics combinations, e.g. ABS/ PBTP or nylon/thermoplastic PU, the attainable bond strength of the composite is important under both mechanical load and influence of media. The bond strength is influenced not only by the material combination and the process parameters but also by flow and cooling conditions in the mould as well as by the part design. The injection moulding process is experimentally analysed by moulding specimens out of two compatible thermoplastics under variation of the processing conditions. The bond strength is characterised by tensile tests. It is shown that the achieved bond strength depends strongly on the distance from the gate and the flow direction in addition to the injection parameters. 6 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.636698 Item 264 Journal of Non-Newtonian Fluid Mechanics 68, Nos.2-3, Feb.1997, p.153-67 NUMERICAL SIMULATION OF MULTILAYER INJECTION MOULDING Manogg G J; Townsend P; Webster M F Swansea,University of Wales The finite element simulation of multilayer injection moulding in an axisymmetric cup-shaped geometry was

82

carried out. The residual thickness of the outer material could be investigated at any stage of the filling process. The occurrence of material breakthrough was predicted and physically feasible results were obtained for different injection delay times. Tracking of both a free filling and a fluid/fluid front was performed using different techniques. Location of different material positions was governed by point inclusion algorithms. Shear flow instabilities at the fluid/fluid interface were investigated for various core-skin material combinations. 16 refs. (Polymer Melt Rheology Conference, Aberystwyth, UK, Sept.1995) EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.636504 Item 265 Plastics World 55, No.3, March 1997, p.13-5 CO-INJECTION MOULDING: OLD NEWS OR NOT? Betts T Battenfeld of America Inc. Designers are becoming more aware of the coinjection process, and more important, its cost-saving possibilities are becoming clear. The process permits a wide range of performance properties based on three basic combinations: compact outer skin/foamed core, compact outer skin/compact core, and foamed or flexible outer skin/compact core. Coinjection can provide EMI shielding without plating, soft touch with rigidity and the use of recycled/reclaim materials. USA

Accession no.636259 Item 266 Revue Generale des Caoutchoucs et Plastiques No.748, March 1996, p.61-3 French MULTIFLEX, A COMPLETE RANGE OF THERMOPLASTIC ELASTOMERS Milest D; Bayet A Multibase SA The properties, processing and applications of the Multiflex range of styrene-ethylene butylene-styrene block copolymer thermoplastic elastomers (Multibase) are examined. Particular attention is paid to insert moulding, coinjection moulding and coextrusion applications where adhesion to plastics is of importance. EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; WESTERN EUROPE

Accession no.636013 Item 267 Plastics and Rubber Weekly No.1687, 23rd May 1997, p.21

© Copyright 2002 Rapra Technology Limited

References and Abstracts

TWO INTO ONE CAN GO Developed by Addmix, Sequenced Screw Loading exploits the limited mixing performance of standard reciprocating screw injection units to process two materials. While many processors regard the plasticising screw as a mixing device, it is in fact designed for conveying and preparation of material. Addmix takes advantage of this in its single-screw sandwich moulding technology. The company uses a special two-component dosing unit to load the screw with a predetermined sequence of two materials. Because very little distributive mixing occurs during plastification, the two materials are transported through the injection unit as discrete zones. This allows sandwich mouldings to be produced that compare with those from traditional twin injection unit processing machines. Details are given. ADDMIX EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.635614 Item 268 Kunststoffe Plast Europe 87, No.3, March 1997, p.24-5 HOT RUNNER SYSTEMS WITH VALVE GATES Gauler K Positively actuated valve gates can improve the quality of parts moulded with hot runner systems. Moreover, some special injection moulding techniques are only possible with valve gates. Aspects discussed included optimisation of moulded part quality, cycle time reduction, moulding processes made possible due to valve gates, controlled volumetric flow/balancing, elimination of weld lines, in-mould decorating/laminating, reduction of mould clamp force, gas-assisted injection moulding, structural foam moulding, the co-injection moulding process and control of valve gates. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

SEMPAC SWITZERLAND; WESTERN EUROPE

Accession no.630220 Item 270 Modern Plastics International 27, No.3, March 1997, p.74-6 HOT RUNNERS BOOST COINJECTION MOULDING PROCESS Moss M D Dynisco Inc. Coinjection consists of injection moulding two or more materials, one of which forms an outer skin layer surrounding one or more core layers. Benefits of the technology include the use of recycled material for the core which can result in cost savings, the core layer can have a specific property such as an oxygen permeation barrier, and a painted skin appearance can be produced with an unpainted core by using a moulded-in paint process. Runner design and mould-fill analysis are critical in maximising core-skin ratios. Process requirements are discussed. USA

Accession no.628905 Item 271 Industria della Gomma 39, No.10, Oct.1995, p.42/5 Italian MULTI-COLOUR AND MULTI-COMPONENT PARTS WITH ARBURG ALLROUNDER PRESSES Processes for multi-colour and multi-material injection moulding using Allrounder presses developed by Arburg are described. ARBURG MASCHINENFABRIK EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.631982

Accession no.621095

Item 269 European Plastics News 24, No.4, April 1997, p.30-1 SMART MOVES Anscombe N

Item 272 Plastics News(USA) 8, No.41, 9th Dec.1996, p.11 CONFERENCE EXPLORES OPTIONS OF COINJECTION Bregar W

Five years ago, a Swiss manufacturer of machines that produce semiconductors and printed circuit boards decided to enter the smart card manufacturing market. Sempac’s Compact Line uses injection moulding for the one-step manufacture of smart cards. By over-moulding around the base of the electronic module, the card must be practically destroyed in order to remove the chip. The manufacturing cell includes all the ancillary equipment for the injection moulding machine and is a closed loop system.

Although coinjection - moulding that uses one core material and another skin material - has been around for around 20 years, many moulders still know very little about it, according to speakers at a recent conference. The Benchmarking Program on Coinjection Molding, sponsored by the the SPI’s Midwest Regional Office, drew about 80 people to Cincinnati Milacron’s Plastics Machinery headquarters in Batavia. Bemis Manufacturing of Sheboygan Falls, Wisconsin, started coinjection

© Copyright 2002 Rapra Technology Limited

83

References and Abstracts

moulding to consume its own regrind. Highlights of the conference are presented. BEMIS MANUFACTURING CO.; CINCINNATI MILACRON INC.; INCOE INC.; BATTENFELD OF AMERICA INC.; GE PLASTICS; BATTENFELD GMBH; SPI

Item 276 Plast’ 21 No.46, Oct.1995, p.24 Spanish PROCESS RATIONALISATION AND INCREASED EFFICIENCY THROUGH ROBOTS

USA

The use of an industrial robot designed by Wittmann in a specialised injection moulding application is described. The process uses two machines and involves the injection moulding of a thermoplastic component which is subsequently overmoulded with a thermoset. WITTMANN ROBOT SYSTEMS

Accession no.618609 Item 273 Canadian Plastics 54, No.8, Nov.1996, p.14-6 DEVELOPMENTS IN INJECTION MOULDING TECHNOLOGY LeGault M Developments in injection moulding are reviewed with reference to the Canadian plastic moulding industry, and the processes which Canadian moulders can use to capitalise on growth and new market opportunities. Technologies reviewed include powder injection moulding, low pressure injection moulding, and multigate coinjection hot runner technology. CANADA

Accession no.618446 Item 274 Plastics Southern Africa 26, No.6, Nov.1996, p.36/8 SANDWICH-MOULDING OF PET PREFORMS This article looks at the increasing use of sandwich moulding technology (where a layer of recycled material is sealed within a “skin” of virgin material) by PETP preform manufacturers. Injection moulding machinery from Stork Plastics Machinery of the Netherlands is highlighted, as the company has targeted this technology for a continuous development programme. STORK PLASTICS MACHINERY EUROPEAN COMMUNITY; EUROPEAN UNION; NETHERLANDS; WESTERN EUROPE

Accession no.618126 Item 275 Plastics News(USA) 8, No.36, 4th Nov.1996, p.5 NEW AUTO WORK DRIVING REHAU EXPANSION Lauzon M Rehau Inc. plans to expand injection moulding capacity at its Cullman, Alabama plant to supply new automotive contracts. The article supplies details of the expansion plans which include adding dual injection moulding capacity, and almost doubling the plant’s size. REHAU INC. USA

Accession no.617648

84

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.616945 Item 277 Plastiques Flash No.283, Aug./Sept.1995, p.114-5 French MICRONOZZLES FOR MICROCOMPONENTS Details are given of a 16-cavity hot runner mould developed by Gunther for the injection moulding of microswitches incorporating thermoplastic elastomer and glass fibre-reinforced nylon 66 components. GUNTHER HEISSKANALTECHNIK GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.616902 Item 278 Injection Molding 4, No.11, Nov.1996, p.106/12 COINJECTION HOT RUNNER BASICS Kirkland C Coinjection moulding with hot runners is a popular topic. Coinjection, or sandwich moulding, is the injection moulding of two or more plastic materials where a thin outer skin layer (for instance an expensive engineering resin) is formed surrounding one or more core layers (an inexpensive material or recyclate). The benefits of the process increase when hot runners are used. However, according to Dynisco’s Kona Hot Runner Systems, little information has been published acquainting moulders with basic details about the process. The following solutions to basic processing problems should help to familiarise with the advantages and disadvantages of coinjection moulding. DYNISCO INC.; KONA HOT RUNNER SYSTEMS USA

Accession no.614294 Item 279 Advanced Materials & Processes 150, No.5, Nov.1996, p.4

© Copyright 2002 Rapra Technology Limited

References and Abstracts

OVERMOULDED PARTS MADE FROM SINGLE PLASTIC According to Ferromatik Milacron, overmoulding no longer needs to be beyond the reach of the majority of plastics injection moulders. The process for producing hinge or ball-and-socket joints complete, without postmoulding assembly, used to require machines designed to accommodate two different materials. However, by using a technique called ice-cold moulding, Milacron engineers have performed overmoulding with just one material using a standard Ferromatik Milacron injection moulding machine. Key to the new technique is a set of cooling inserts, placed inside the mould and maintained at a temperature of about 0 deg.C. Even for established overmoulders, lower equipment costs would translate into a production cost saving of about 10% per part. Details are given. MARKETING SUPPORT SERVICES INC.; FERROMATIK MILACRON USA

Accession no.614256 Item 280 Kunststoffe Plast Europe 86, No.9, Sept.1996, p.13-4 CASCADE INJECTION MOULDING AVOIDS WELD LINES Homes W Eurotool Heisskanalsysteme GmbH By means of two special purpose techniques of injection moulding, it is shown to be possible to influence the locations of weld lines. In sequential injection moulding they are displaced to uncritical areas of the moulding. In cascade injection moulding mouldings are produced free from weld lines even though on thin-walled mouldings the length amounts to a multiple of the flow path of the melt. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.610536 Item 281 Kunststoffe Plast Europe 86, No.9, Sept.1996, p.11-2 INJECTION MOULDING OF PA 6/TPU COMPOSITES Ehrenstein G W; Kuhmann K Erlangen-Nurnberg,University The injection moulding of rigid/flexible combinations of materials, specifically nylon 6 and thermoplastic polyurethane is examined with reference to the influence of the mould flow and cooling conditions on the bond strength achieved. Selective variation of the machine settings enables the production of moulded parts with an improved and more uniform bond strength to be achieved. 3 refs.

© Copyright 2002 Rapra Technology Limited

EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.610535 Item 282 Antec ’96. Vol.I. Conference Proceedings. Indianapolis, 5th-10th May 1996, p.1182-6. 012 ULTRASONIC TECHNIQUE FOR MONITORING THE INTERFACE IN MULTI-LAYER POLYMER FLOWS Magda J J; Parrott M L; Thomas C L; Lawson D R Utah,University; 3M Corp. (SPE) An ultrasonic sensing technique for detecting interfaces and measuring the thickness of layers occurring in multilayer polymer flows is described. Preliminary experiments were undertaken to evaluate the sensitivity of an ultrasonic pulse to interfaces between acoustically similar but immiscible fluids. A simple room temperature flow cell simulating conditions during coextrusion or coinjection moulding and fitted with an ultrasonic transducer demonstrated the ability of this technique to detect interfaces and measure layer thicknesses in stratified polymer flows. Application of the technique to practical industrial processes was investigated in a laboratory experiment using a coinjection moulded sample. 9 refs. USA

Accession no.609256 Item 283 Modern Plastics International 26, No.11, Nov.1996, p.99 MULTI-MOULD INJECTION SYSTEMS REDUCE OVERHEAD EXPENSES Hettinga Technologies’ multi-station injection moulding system for pallets produces 60 to 80 parts/h. The company’s Controlled Density Molding process can be used to vary wall thickness between 3 and 25mm from one cycle to the next. Pallets of different size, weight or shape can be moulded at each station. Presma’s Roto Sistem BIC 10,000/600/5 works on a similar concept. The first model was recently delivered to a German moulder of garden tables and chairs. A coinjection unit serves five moulds, but the former is fixed and the latter move into position on a carousel. HETTINGA TECHNOLOGIES INC.; PRESMA SPA EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; USA; WESTERN EUROPE

Accession no.608974 Item 284 Plastics and Rubber Weekly No.1661, 8th Nov.1996, p.49 RUNNER-LESS MOULDING WITH TWO MATERIALS Hot runner systems Ewikon has supplied a large number of systems for multi-component moulding. The company

85

References and Abstracts

believes that its HPSI internally heated hot runner components are particularly suited to this type of application. Using two feed channels on centres 35mm apart running at temperatures of 190C and 290C, the temperature in the body of the manifold does not exceed 65C. This means that it becomes a practical possibility to run two different materials with widely differing process temperatures through a single manifold. EWIKON GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.608910 Item 285 Injection Molding 4, No.9, Sept.1996, p.46/50 THREE-SHOT HOTSHOT OPENS DESIGN DOORS Maniscalco M Three-shot moulding is described, and in particular the production of the Trio knob by Sifam Ltd., is examined. Sifam claims to have taken the lead among custom moulders by specialising in multishot capabilities. The advantages of the process, its costs, and possible material combinations are discussed. SIFAM LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.608144 Item 286 Antec ’96. Vol.I. Conference Proceedings. Indianapolis, 5th-10th May 1996, p.655-62. 012 ONE-SHOT MANUFACTURING: WHAT IS POSSIBLE WITH NEW MOULDING TECHNOLOGIES Stevenson J F GenCorp Technology Center (SPE) A number of new techniques for polymer processing are examined, including gas-assisted, fusible core, low pressure and lamellar injection moulding, advanced blow moulding, thermoplastic sheet composite processing, reactive liquid composite moulding, microcellular plastics processing, and multi-material and multi-process technologies. The advantages and disadvantages of these processes, their applications and types of materials used are reviewed. 13 refs. USA

Accession no.606395 Item 287 Injection Molding 4, No.8, Aug.1996, p.81-2 COINJECTION FOR PAILS Neilley R

86

The article supplies details of an 1100-ton coinjection machine from MIR SpA, that will be used by Plastican Inc., a US-based container manufacturer, to mould 5 gallon paint tins. The article compares the advantages of using the coinjection unit with using two separate machines, in terms of energy reduction, production time and overall cost. MIR SPA; PLASTICAN INC. USA

Accession no.604492 Item 288 Warrington, 1993, pp.6. 11ins. 7/12/95. PRODUCTION PLANT AND MACHINERY FOR INJECTION MOULDING, PUR-FOAMING, EXTRUSION Krauss-Maffei (UK) Ltd. Machines are described and illustrated from KraussMaffei for the production of injection mouldings, the foaming of polyurethane, and extrusion. Brief details are given of injection moulding machines in the M, B and C series, injection moulding machines for thermoset, BMC/ TMC, rubber and silicone rubber processing, and multicomponent injection moulding machines. The foaming machines include pump metering, and piston metering machines, and details are given of mould carriers, mixing heads and PUR production line technology. Extrusion lines for pipe production, profile dies and calibration systems, single, twin and co-extruders, and pipe die heads and calibration systems are described. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.603972 Item 289 Injection Molding 4, No.7, July 1996, p.77 MANUFACTURING: SINGLE MATERIAL OVERMOULDING WITH THE “ICE-COLD” PROCESS This article describes the process and advantages of icecold overmoulding. The cooling permits the overmoulding of moving parts using just one material, rather than the two that overmoulding typically requires. FERROMATIK MILACRON USA

Accession no.603684 Item 290 Antec ’96. Vol.I. Conference Proceedings. Indianapolis, 5th-10th May 1996, p.460-5. 012 DYNAMICS OF THE MELT-AIR INTERFACE: THE KEY TO UNDERSTANDING THE UNIQUENESS OF INJECTION MOULDED PARTS Schmidt L R Schmidt L.R.,Associates

© Copyright 2002 Rapra Technology Limited

References and Abstracts

(SPE) An examination is made of the dynamics of the melt-air interface or flow front in injection moulding and their influence on the resultant structures and property profiles of injection moulded parts. Reference is made to a number of experimental and theoretical studies of flow in injection moulding. 15 refs. USA

Accession no.602954 Item 291 Modern Plastics Encyclopedia 1996, p.D-88-135 INJECTION MOULDING MACHINES A comprehensive list of injection moulding machines is presented. Details include clamp force, clamping unit, shot capacity, plasticating capacity, screw L/D, tiebar clearance, die space, injection stroke, injection pressure, floor space, weight, model and supplier. Machines are available to process thermoplastics and thermosets, including elastomers and reinforced polyester, for insert moulding and coinjection. Names and addresses of suppliers are included. WORLD

Accession no.597587 Item 292 Plastics World 54, No.7, July 1996, p.17 HUSKY MAKING RANGE OF LARGE PRESSES IN US Smock D Husky’s new large machine production plant in Pittsfield, Mass. has shipped more than six presses since it opened nine months ago and reports an order backlog of about six months. The plant is one of only three North American sites that produce presses up to and above 4,000 tons in clamp force. Husky will probably add another type of large-tonnage press early next year. The E Series is an all-new design in two-platen machines with smaller footprint and faster cycle time. Another press made in the plant is a large tonnage press for lost core moulding, the first ever made in North America. HUSKY INJECTION MOLDING SYSTEMS USA

Accession no.597539 Item 293 Plastics and Rubber Weekly No.1645, 19th July 1996, p.9 BATTENFELD MARKS OUT TIEBARLESS INTENTIONS Battenfeld’s prototype tiebarless machine has been trialled with a local Austrian custom moulder and is reported to

© Copyright 2002 Rapra Technology Limited

have performed well. The 60 tonne BA600CDH machine uses a C-frame clamp frame, to which the end stock and fixed platen are rigidly mounted. Battenfeld says it will only sell CDH machines if the price covers the additional manufacturing costs incurred. Battenfeld is currently investigating hydraulic/electric hybrid options. The modular design of the all-electric SE range is said to make construction of hybrid machines relatively simple. Three machines configured for multi-component work were on show at the company’s recent open house. BATTENFELD GMBH AUSTRIA; WESTERN EUROPE

Accession no.594970 Item 294 Injection Molding 4, No.5, May 1996, p.85-6 NEW COMPANY MOVES COINJECTION FROM THE MACHINE TO THE MOULD Kirkland C Multi-gate coinjection hot runner technology has been developed by Kortec Inc., which uses a hot runner system that has separate flow channels for the skin and core materials. The two flow streams are joined at each hot runner nozzle. The technology moves the joining of skin and core materials such as an expensive virgin skin and a cheaper postconsumer recyclate core, into the mould, thus moving coinjection out of expensive, process-dedicated moulding machines. As a result, less complex two-colour multi-media moulding machines can be used which cost 25-40% less than coinjection machines. KORTEC INC. USA

Accession no.592430 Item 295 Emerging Technologies Retec ’95. Conference proceedings. Erie, Pa., 9th-10th Aug.1995, paper 4. 8 IN-MOULD ASSEMBLY TECHNIQUE REVEALS NEW APPLICATIONS Richmond D Ferromatik Milacron (SPE,Northwestern Pennsylvania Section; Penn State Erie,Behrend College Plastics Technology Deployment Center; US,National Tooling & Machining Assn.) Aspects of modern injection molding with more than one material are described, including the benefits to move from conventional injection moulding to highly advanced multi-component technology. Various applications are addressed with emphasis placed on the use of compatible and non-compatible materials. Thermoplastic elastomers are given particular attention. Realised benefits of the technology are cost reduction by means of in-mould assembly and/or an increase in value by product enhancement. Also reviewed are material selection, mould

87

References and Abstracts

technology and injection moulding equipment requirements. 6 refs. USA

Accession no.591693 Item 296 British Plastics and Rubber June 1996, p.4-6 3D CAD PUTS PRODUCT DESIGNERS IN THE DRIVING SEAT Fearis P; McMillan A PDD; Sifam Three-dimensional computer aided design linked to computer aided mould machining has made possible shapes and concepts hitherto out of the economical reach of the traditional product designer and mould maker. Advances in computing software and hardware are enabling advanced manufacturing processes such as multi-shot moulding to be adopted more easily and economically. Examples are presented illustrating the effects on final product cost through the use of multishot moulding to replace assembly and decoration processes. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.591176 Item 297 Modern Plastics International 26, No.5, May 1996, p.98 FERROMATIK MILACRON: INNOVATIVE INJECTION MOULDING Developments by Ferromatik Milacron in recent years include the Mono-Sandwich process, multi-component injection moulding and the Airpress-III process. Today, Ferromatik Milacron and Cincinnati Milacron are offering a line of all-electric units which have a clamping force range from 300 to 6,600kN. The Elektra 660E, the world’s largest all-electric injection moulding machine with a clamping force of 6,600kN, was introduced at last year’s K Show. FERROMATIK MILACRON GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.589716 Item 298 Reinforced Plastics 40, No.5, May 1996, p.20 LAYERED GLASS REINFORCED NYLON CORES PROVIDE HIGH STRENGTH INTAKE MANIFOLDS Fuji Heavy Industries has developed a moulding method for producing lightweight intake manifolds at reduced cost and which eliminates the problems of the lost core process.

88

A two layer blow moulded core is produced, consisting of a smooth inner layer of nylon 6 and an outer layer of 30% GRP nylon 6. The core becomes the inner layer of the injection moulded product, 45% GRP nylon 6. Meanwhile, BASF continues to improve the lost core technique and has designed a computer algorithm which it says can predict the tendency of core shift during injection moulding. The algorithm also reduces variations in the wall thickness of the manifold. FUJI HEAVY INDUSTRIES LTD.; BASF CORP. JAPAN; USA

Accession no.589608 Item 299 Kunststoffe Plast Europe 86, No.3, March 1996, p.14-6 MULTICOLOUR AND MULTICOMPONENT TECHNOLOGY. INJECTION MOULDING MULTIFUNCTIONAL AUTOMOBILE COMPONENTS Steinbichler G Engel Maschinenbau GmbH Combining different colours of the same plastics requires special processing technologies but also enables different functions to be integrated into one component and for component manufacture to be rationalised. The process is described in detail and bond strength between different thermoplastic elastomers and thermoplastics is tabulated. 6 refs. Translated from Kunststoffe, 86, No.3, 1996, p.31820. AUSTRIA; WESTERN EUROPE

Accession no.587207 Item 300 IRC ’95 Kobe International Rubber Conference. Conference proceedings. Kobe, 23rd-27th Oct.1995, p.91-4. 012 ADHESION OF ADDITION CURE SILICONES TO THERMOPLASTIC Fujiki H; Shudo S Shin-Etsu Chemical Co.Ltd. (Japan,Society of Rubber Industry) A new addition curing silicone rubber having selective bonding to polycarbonate, PBTP, etc. without adhering to the mould (metal) in thermoplastics insert molding and co-injection moulding is described. JAPAN

Accession no.586128 Item 301 Eureka 16, No.3, March 1996, p.24/7 MULTIPLE MOULDINGS OFFER ALL FUNCTIONS Shelley T

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Three-shot moulding is discussed, with reference to its use in producing large complex products in vastly different materials in a single cycle. The process requires proper choice of materials and process parameters, and offers benefits in terms of enhanced durability, improved feel, and lowered costs. Examples of applications in electrical consumer goods are given. SIFAM; PANKHURST DESIGN & DEVELOPMENTS EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.585473 Item 302 Kunststoffe Plast Europe 84, No.6, June 1994, p.6-8 German; English COMBINING HARD AND SOFT PLASTICS IN INJECTION MOULDING Jaroschek C; Pfleger W Ferromatik Milacron GmbH; EMS Chemie AG The two-component process of injection moulding is discussed, and the advantages it affords in enabling different materials to be injection moulded together in a single part. The combination of hard and soft polymers is examined, in which a thermoplastic and a thermoplastic elastomer are processed together. A survey of processing technology is included, and particular attention is paid to the factors influencing bond strength. Examples are given of typical applications for the two-component process. 9 refs. AUSTRIA; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.585091 Item 303 Innovations in Interior and Exterior Plastics for Automotive Applications. Retec proceedings. Dearborn, Mi., 8th-9th Nov.1995, p.153-7. 63Tr.Ro ADVANCED PROCESSING OF AUTOMOTIVE TPO Denison B R D & S Plastics International (SPE,Detroit Section; SPE,Automotive Div.) Advancements in thermoplastic olefin formulations and advanced processing techniques are leading to enhanced cost/performance in automotive applications. Coinjection moulding, gas injection moulding, and in-mould film technologies are combining and enhancing novel polyolefinic materials in current and projected applications. Cost savings, weight savings and systems integration opportunities are the likely result. USA

Accession no.583855 Item 304 Injection Molding

© Copyright 2002 Rapra Technology Limited

4, No.2, Feb.1996, p.38 THE LOWDOWN ON LOST CORES Typical applications for which lost core moulding are suitable are described, with specific details relating to under-the-bonnet applications. Comments as to the advantages of the process are reported, with reference to the experiences of Electrovert’s Metal Dispensing Div. The main advantages include design flexibility and accurate part-to-part repeatability. ELECTROVERT-FRY LTD.,METAL DISPENSING DIV. USA

Accession no.582772 Item 305 Plastics and Rubber Weekly No.1625, 1st March 1996, p.22 BIRKBYS INVESTS IN MULTI-COLOUR Within the next few weeks Birkbys Plastics will take delivery of an 1100 tonne Engel two colour injection moulding machine, giving it one of the largest twin shot machines in the UK. The machine is being installed for production of large projected area moulded automotive components which traditionally have an extruded elastomer seal applied in a secondary application. Using sliding core tool technology it is possible to mould these parts over two consecutive cycles, producing an integrated part at lower cost and higher quality. Automation is widely applied at Birkbys. Among the most recent installations is an automated insert loading and parts removal system from Pressflow. BIRKBYS PLASTICS LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.582287 Item 306 Plastics and Rubber Weekly No.1625, 1st March 1996, p.21 MAKING MULTI-SHOT WORK One year ago, Sifam installed a three-colour injection moulding machine and set out to build a multi-material custom moulding business. One machine, a 175 tonne Engel, was installed solely for custom moulding and is currently making dual material handles for the Alessi kettle. The company started making two colour knobs in the late 1980s and currently produces more than 30 million knobs each year. Sifam has manufactured the tooling for Philips’ latest design of switches for its standard range of kettles and is moulding the parts. The company is currently building an eight cavity mould for production of two colour control knobs. This mould uses interchangeable inserts to allow a number of variations to be made. SIFAM EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.582286

89

References and Abstracts

Item 307 European Rubber Journal 178, No.2, Feb.1996, p.16-8 PLASTICS: PANACEA OR PROBLEM? White L The use of plastics to replace metals as a rigid supporting material for rubber parts eliminates the need for costly and labour intensive metal preparation. Huls has developed some plastics and rubber compositions, patented under the K&K name, where adhesion is provided by the interpenetration of bonds between the composites. It is claimed that while the machinery makers have developed technical solutions for co-moulding rubber to plastics, the materials available currently are limited. Ease of manufacture has caused a trend towards more use of co-moulding/over moulding techniques using rubber or liquid silicone rubber or thermoplastic elastomers with plastics. WESTERN EUROPE-GENERAL; WESTERN EUROPE

Accession no.579788 Item 308 Modern Plastics International 26, No.1, Jan.1996, p.19-20 MANIFOLD MIXING UNIT PUTS A SKIN LAYER ON MOULDINGS Mapleston P A small mixing unit that fits between nozzle and mould in injection and blow moulding machines can be used to produce sandwich mouldings in which colourants and other surface active agents are present only in the skin layer of the moulding. The Addmix system works with any type of additive in liquid form. From January, the company will supply off-the-shelf manifolds that attach to the back of each mould. The additive is mixed into the polymer melt between the end of the injection barrel and the mould. By selective addition of the additive into the first part of the shot, the part which becomes the skin layer of the moulding, processors can cut down on their additives consumption by as much as 80%. ADDMIX EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.578180 Item 309 Antec 95. Volume III. Conference proceedings. Boston, Ma., 7th-11th May 1995, p.4036-40. 012 DEVELOPMENT OF A TOTAL QUALITY COINJECTION MOULDING PROCESS Martin M F; Parsons J L; Albrecht L Dow Plastics; Bemis Manufacturing Co. (SPE) New horizons for injection moulded parts are being developed through the introduction of innovative and enabling manufacturing techniques developed through

90

informal strategic partnerships or vendor alliances. A project is described where partnerships are formed to develop the co-injection moulding process and meet new plastic industry needs. Aspects covered include the challenge, machine control, machine design and process parameter verification. 18 refs. USA

Accession no.577923 Item 310 Antec ’95. Vol.II. Conference Proceedings. Boston, Ma., 7th-11th May 1995, p.2906-10. 012 APPLICATION OF SCANNING ACOUSTIC MICROSCOPY TO INJECTION MOULDED SEMI-CRYSTALLINE THERMOPLASTICS Kuriyama T; Narisawa I; Abe T Yamagata,University; Japan,Government Industrial Research Institute (SPE) Low frequency scanning acoustic microscopy was used to study the microstructure of injection moulded plastics specimens. Polymers examined included PP with and without calcium carbonate filler, HDPE, polyetherimide, polycarbonate and a liquid crystal polymer. 9 refs. JAPAN; USA

Accession no.576636 Item 311 Decorating and Joining of Plastics. Retec proceedings. Farmington, Ct., 17th-18th Sept.1995, p.203-7. 8(10)8(11)34 INNOVATIVE PRODUCT ENHANCEMENT THROUGH IN-MOULD ASSEMBLY AND DECORATING Mauro L J Ferromatik Milacron (SPE,Connecticut Section; SPE,Decorating Div.) The use of the multi-component injection moulding process to reduce overall part costs through in-mould assembly and to enhance the overall product quality and appearance through in-mould decorating is discussed. The basic concepts of multi-component moulding, including materials selection, are described. Use of this technology is increasing rapidly worldwide. Various applications are addressed with examples of actual usage. Also included are brief details of the patented mono-sandwich process for the production of plastics sandwich structures. 2 refs. USA

Accession no.575801 Item 312 Injection Molding 3, No.11, Nov.1995, p.90/6 LATEST WRINKLES IN LOST-CORE MOULDING

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Lost-core technology for the manufacture of intricate thermoplastics components is reported to have commenced with Ford Europe’s air-intake manifold for its 1.6 litre diesel engine and BMW’s cell for manufacturing the manifold on a straight 6. Since then there have been other applications including tennis racquets, pump impellers and housings and hot water heating pumps. Advantages cited for the process include weight savings, reduced manufacturing costs, elimination of machining, parts are ready for assembly from the line, parts consolidation, complex groups, reduced gas flow resistance and reduced noise. Aspects emphasised include core casting, handling of cores, overmoulding with plastic, melting out the core and final assembly. FORD MOTOR CO.; BMW AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; USA; WESTERN EUROPE

Accession no.573490 Item 313 Antec ’95. Vol.II. Conference Proceedings. Boston, Ma., 7th-11th May 1995, p.1788-93. 012 STRUCTURAL GRADIENTS DEVELOPED IN INJECTION MOULDED SYNDIOTACTIC POLYSTYRENE (S-PS) Ulcer Y; Cakmak M; Miao J; Hsiung C M Akron,University,Inst.of Polym.Engineering; Southwestern Louisiana,University (SPE) Transmission optical microscopy, matrixing microbeam wide-angle X-ray diffraction and DSC studies were used to investigate structure formation during the injection moulding of syndiotactic PS. The results showed that the structure formed at a given location was dictated by the competition between the cooling rate, thermally induced crystallisation and stress induced crystallisation. Mould temperature, injection speed and mould geometry were the parameters determining which of these mechanisms would dominate. 22 refs. USA

Accession no.568173 Item 314 Plastics on the Road ’94. Conference Proceedings. Solihull, 28th-29th Nov.1994, paper C. 63Tr.Ro ENVIRONMENTAL CONCERNS OVER VOCS AND GRANULAR INJECTED PAINT TECHNOLOGY Easterlow R; Rowberry P J Rover Advanced Technology Centre; Warwick Manufacturing Group (Institute of Materials; Institution of Mechanical Engineers; Industrial Technology Magazine) The amount of volatile organic compounds (VOCs) being released into the atmosphere from some finishing industries using solvent-based paints is resulting in

© Copyright 2002 Rapra Technology Limited

increasing environmental concern. This has led to a tightening of legislation for their reduction. The finishing industry must therefore improve fume filtration or seek an alternative. The development of a granular injected paint technology, based on the formulation of a thermoplastic paint and which can by using the dual injection moulding process be incorporated into a moulded component in a single operation, is described. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.564918 Item 315 International Polypropylene Conference. Conference Proceedings. London, 24th-25th Oct.1994, p.156-64. 42C12 FOAM SANDWICH FOR AUTOMOTIVE BODY PANELS Atkinson P; Bagdatlioglu I BASF UK Ltd.; Plastic Design Solutions UK (Institute of Materials; BASF AG; European Chemical News; Montell Polyolefins) Foam sandwich has seemed for many years to have had much to offer, and yet has rarely been exploited commercially. Details are given of how a foam sandwich bootlid for the Ford Escort CE14 Cabriolet was designed, manufactured and tested. During the project, much was learned about the injection process as well as the properties and failure modes of composite foam sandwich panels. FORD MOTOR CO. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.564893 Item 316 Revue Generale des Caoutchoucs et Plastiques No.736, Nov.1994, p.44-6 French SEQUENTIAL INJECTION MOULDING Gazonnet J P Pole Europeen de Plasturgie The sequential injection moulding process and some of its applications are described, and details are given of software developed by Pole Europeen de Plasturgie and SISE for the control of the process. SISE EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; WESTERN EUROPE

Accession no.563199 Item 317 Plastiques Modernes et Elastomeres 46, No.9, Nov.1994, p.41-2 French SEQUENTIAL INJECTION MOULDING: AN ALTERNATIVE

91

References and Abstracts

The principles and advantages of sequential injection moulding are discussed, with particular reference to the possibility of eliminating or relocating weld lines. The use of the process in the insert moulding of decorative products and the manufacture of GRP structural parts is described. SISE; POLE EUROPEEN DE PLASTURGIE EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; WESTERN EUROPE

Accession no.563179 Item 318 Plastics and Rubber Weekly No.1602, 8th Sept.1995, p.6 MOULDING FIGURES FIND A NEW NICHE Niche Plastics is a new UK company producing a multicomponent system for the enclosed packaging and disposal of sanitary towels, condoms and other hygiene items. Each system features the creation of discrete, film packed parcels, in a free standing container. It has a tamper proof lid and requires the user to rotate the twist cap twice to seal the discarded item. When full, the container is opened and the contents, encased in a tubular film, are removed for hygienic disposal. The new business has involved an investment of some 1.2m pounds sterling, centred around eight Toshibas in the range 55 to 450 tonnes, with two further units to come. The unit consists of a 14 component moulding and assembly programme involving a range of performance plastics, notably polyacetal, ABS, polycarbonate and PP. NICHE PLASTICS EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.560728 Item 319 Antec 95. Volume I. Conference proceedings. Boston,Ma., 7th-11th May 1995, p.760-4. 012 EXPERIMENTAL STUDY OF SIMULTANEOUS CO-INJECTION MOULDING PROCESS Somnuk P; Smith G F Warwick,University (SPE) The simultaneous co-injection moulding process is studied and a new method of mould filling is suggested. The main advantage of this technique is that the coinjection process is controlled in virtually an identical manner to conventional ‘compact’ injection moulding due to the fixed length of the simultaneous phase. A further advantage of this technique is that materials with a broader range of viscosities may be utilised. Generally, in order to obtain an optimum product, it is necessary to select materials which lie within the specified viscosity ratio range. The implication of this technique requires further investigation with regard to the mould filling pattern for more complex geometries. 16 refs.

92

EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.558971 Item 320 Antec 95. Volume I. Conference proceedings. Boston,Ma., 7th-11th May 1995, p.742-. 012 MULTI-COMPONENT INJECTION MOULDING: INFLUENCE OF PROCESS PARAMETERS ON THE ADHESION OF RIGID-FLEXIBLE COMBINATIONS Micheali W; Brinkmann S Institut fuer Kunststoffverarbeitung (SPE) Over the past few years, the multi-component injection moulding of parts using combinations of thermoplastics and thermoplastic elastomers has taken on increasing importance. One of the main problems encountered with these parts is the adhesion of the two materials. This adhesion is conditioned by the chemical structure (polar, non-polar) and by the process parameters (e.g. temperature, time, pressure). The effect of the processing conditions on the contact layer is investigated. Once this is known, it is possible to rapidly optimise the adhesion between the different components in multi-component injection moulding. 6 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.558969 Item 321 Antec 95. Volume I. Conference proceedings. Boston,Ma., 7th-11th May 1995, p.581-5. 012 NEW DEVELOPMENTS IN MULTI-MATERIAL MACHINE DESIGN Buters V E; Elward J Husky Injection Molding Systems Ltd. (SPE) Available methods for multi-material moulding are reviewed and the state of the art in multi-material machines is discussed. Vertical clamp injection moulding machines are the dominant design today. However, horizontal machines can offer a viable alternative. CANADA

Accession no.558944 Item 322 Antec 95. Volume I. Conference proceedings. Boston,Ma., 7th-11th May 1995, p.520-4. 012 HIGH GAS BARRIER CONTAINER USING COINJECTION MOULDING METHODS Seki T; Katoh T; Kubota S Toppan Printing Co.Ltd.; Nissei Plastic Industrial Co.Ltd. (SPE)

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Three injection units are used to produce a barrier food package having a PP-based multilayered body wall including an EVOH layer. This container has the same mechanical strength as a single-layer PP container, but superior oxygen permeability. 3 refs. JAPAN

Accession no.558933 Item 323 Antec 95. Volume I. Conference proceedings. Boston,Ma., 7th-11th May 1995, p.451-5. 012 APPLICATION OF SIMULTANEOUS COMPOSITE INJECTION MOULDING Hamada H; Futamata K; Yamauchi S; Tomari K; Yokoyama A Kyoto,Institute of Technology; Matsushita Electrical Works Ltd.; Osaka,Municipal Technical Research Institute; Mie,University (SPE) Simultaneous composite injection (SCI) moulding is a category of two-colour injection moulding. The SCI moulding machine has two injection units and two nozzles, and a mould with two sprues. Materials simultaneously flow into one common cavity through different gates. The ways in which SCI moulding can be used for different applications are described, the aim being the rational combination of two materials with different properties. 2 refs. JAPAN

Accession no.558865 Item 324 Plastics World 53, No.5, May 1995, p.21-2 CO-INJECTION IS WORTH THE EXTRA EFFORT, EXPERTS SAY Smock D It is claimed that coinjection moulding is an excellent method for using reground or reprocessed material in recycling. The reground material can be used in the core of the part with a virgin material on the skin, maintaining the quality of the part. Coinjection is said to be particularly promising for polyolefin automotive applications. In bumper/fascia applications the skin and core materials can be selected to improve impact, paintability and/or dimensional stability. In interior/exterior trim, expensive coloured plastics can be relocated in the skin only. Higherheat polyolefins can internally reinforce aesthetic grades in wheel covers and other high heat applications. USA

Accession no.552051 Item 325 Plastics and Rubber Weekly No.1583, 28th April 1995, p.13

© Copyright 2002 Rapra Technology Limited

MAKING IT WITH MULTI-SHOT Sifam recently ran a series of seminars to demonstrate the economic and production benefits available through multi-component moulding. The important role of 3D CAD software was discussed. Examples from Sifam’s own production were used to illustrate the relative benefits of overmoulding and insert moulding in two materials. An overmoulded battery case currently produced for a marine radio/phone and a casing incorporating a transparent window were used as examples. Delegates were provided with a quick technical review of multicomponent techniques including the sliding insert system, index plate and rotary table. EMS discussed the three ways of combining plastic melts in the mould: bi-injection, coinjection and injection welding. SIFAM EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.549631 Item 326 Plastics and Rubber Weekly No.1577, 17th March 1995, p.8 MOULDING IN THREE COLOURS Sifam believes that three-shot moulding has a wide scope of application in general manufacturing where its ability to integrate different colours, textures and materials can improve product differentiation. A large part of the company’s existing moulding operation is taken up with a range of control knobs which it markets worldwide to manufacturers of electronic equipment, such as audio mixing desks. Two-colour knobs are produced in polyamide. Soft-touch designs are moulded in PP and Santoprene TPE. Sifam has installed a new Engel threeshot, 80 tonne tiebarless moulding machine. PDD helped Sifam design a three-colour knob to meet customer requirements and also to provide a good demonstration vehicle for its three-shot process. SIFAM EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.545413 Item 327 Injection Molding 3, No.2, Feb.1995, p.65/8 HOT RUNNER SYSTEMS FOR MULTIMATERIAL MOULDING Weick P Husky Injection Molding Systems Ltd. Advantages are described of moulding a complete multimaterial/multi-colour component in one machine versus insert moulding, which is argued to be a labour intensive operation, which can effectively be replaced by the use of state-of-the-art system using multiple injection units. Advantages discussed include reduced scrap, and reduced

93

References and Abstracts

cycle time. The design of multimaterial machines is examined, with particular reference to rotary platen/rotary core machines, standard clamp/multiple injection unit machines, and coinjection moulding. CANADA

Accession no.544989 Item 328 Antec ’94. Conference Proceedings. San Francisco, Ca., 1st-5th May 1994, Vol.II, p.1433-7. 012 EFFECT OF LAMELLAR INJECTION MOULDING ON PROPERTIES OF PC/ABS COMPOSITES Nichols K; Solc J; Barger M; Pawlowski D; Bicerano J Dow Chemical Co. (SPE) Composites consisting of various numbers of layers of polycarbonate and talc filled ABS were prepared by lamellar injection moulding, a process combining coextrusion and injection moulding. The effect of the layered morphology resulting from this process on the tensile, flexural and impact properties and linear thermal expansion coefficient of the composites was investigated, and comparisons were made with the properties of similar materials made by conventional injection moulding. The tensile modulus and thermal expansion results were compared to theoretical calculations. 5 refs. USA

Accession no.544336 Item 329 Modern Plastics International 25, No.3, March 1995, p.36 CLIPS-ON-A-STRING SIMPLIFY AUTOMATIC FASTENING PROCESS Mapleston P The Plastifast system from Tucker involves overmoulding acetal fasteners onto twin monofilaments, also made of acetal, to form a continuous ladder. The company’s principal customer is the automobile industry, but new markets could include electrical/electronic, specifically the personal computer sector. Fasteners with integral, standardised mounting devices at each end are injection moulded in Delrin acetal homopolymer. Two continuous lengths of acetal monofilament fed through the mould serve to join consecutive mouldings together via the mounting devices. The row of fasteners is then wound onto a drum, which is subsequently loaded onto a machine that automatically transports them to the desired position for fastening. TUCKER GMBH EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.544102

94

Item 330 Patent Number: US 5328651 A 19940712 METHOD FOR MANUFACTURING AUTOMOBILE TRIM COMPONENT BY BLOW MOULDING AND INJECTION MOULDING Gallagher M J; Nobbs D Davidson Textron Inc. A plastic unfoamed material and foamed material are coextruded into a multilayer parison, which is then blow moulded to a desired form. After the layers are cured, the article is removed from the blow mould and sectioned into multilayer skin halves and one skin is placed in an injection mould. The core resin, which may be thermoplastic or thermoset, is then injected into the injection mould and onto the skin, the resin being compressed against the skin to produce a shell comprising a resin core layer, intermediate foam layer and decorative outer layer. USA

Accession no.542845 Item 331 Modern Plastics International 25, No.2, Feb.1995, p.24/6 MULTIMATERIAL/MULTICOLOUR SCORES IN NON-LENS SECTORS Synder M R Multi-material/multi-colour injection moulding is making significant inroads in applications such as screwdrivers, food containers and spatulas, although the process is still very successful in its well-established automotive lens niche. Stanley Works has used multi-material moulding to create a grey and yellow screwdriver handle of durable PP and easily gripped thermolastic elastomer. A variety of suppliers of vertical machines are making headway in non-lens applications. Van Dorn Demag recently supplied equipment for automotive instrument panel dials. The automotive supplier bought the equipment for its repeatability and reliability, but also because of the flexibility of injection unit orientation. Arburg supplies a special three-colour set-up for use in moulding tricolour dashboard control pushbuttons. WORLD

Accession no.541400 Item 332 Antec ’94. Conference Proceedings. San Francisco, Ca., 1st-5th May 1994, Vol.I, p.716-20. 012 PART DIMENSIONAL CONSISTENCY WITH DIFFERENT SWITCHPOINT CONTROL TECHNIQUES Wagner M Xerox Corp. (SPE)

© Copyright 2002 Rapra Technology Limited

References and Abstracts

The variability of the dimensions and weight of injection moulded parts was studied as a function of three switchpoint control techniques, i.e. position, cavity pressure and parting line. Two different velocity profiles were used, and the techniques were run at low and high holding pressures and injection velocities. Considering the weight data, cavity pressure and parting line sensing were superior to position switchpoint control. The control technique had the least effect on dimensional consistency and part weight under high injection velocity and holding pressure. 7 refs. USA

Accession no.541186 Item 333 Antec ’94. Conference Proceedings. San Francisco, Ca., 1st-5th May 1994, Vol.I, p.671-9. 012 STUDY OF POLYMER MELT FLOW DURING INJECTION MOULDING USING COINJECTION MOULDING TECHNIQUE Chen S C; Hsu K F; Jung W R Chung Yuan University (SPE) Polymer melt flow during coinjection moulding was studied using alternate sequences of transparent skin PS and coloured core PS. Computer simulations were developed to predict the melt front movement of both the skin and core melts. Various effects on the melt front progression and final distribution were investigated, including nonuniform thickness, flow in a plate cavity with thick ribs, the corner effect and the edge effect. 12 refs. TAIWAN; USA

Accession no.541177 Item 334 Antec ’94. Conference Proceedings. San Francisco, Ca., 1st-5th May 1994, Vol.I, p.554-8. 012 NUMERICAL SIMULATION OF THE SEQUENTIAL FILLING IN INJECTION MOULDING PROCESS Gao D M; Nguyen K T; Girard P; Salloum G Canada,National Research Council (SPE) A numerical model was developed to simulate the sequential filling of complex injection moulded parts of arbitrary shape. The effect of sequential filling was compared with the case in which all gates are opened simultaneously. Significant differences were observed in flow fronts, weld line locations and pressure distributions. Good agreement was found between numerical simulation and experimental results. 5 refs. CANADA; USA

Accession no.541158

© Copyright 2002 Rapra Technology Limited

Item 335 British Plastics and Rubber Jan.1995, p.29 MULTI-VOLTAGE CONTROL ON THE SAME CARD Control of multiple heater configurations in multi-hot runner systems or Seiki Spear thermal gates has become a speciality of PMS Systems. Multi-material/colour moulds require two or more hot runner assemblies within a common moulding system, sometimes using different makes of hot runner system at different voltages within the same mould. PMS has made multi-voltage and dual purpose controllers for several years based on the concept of using a common multi-voltage control card for each zone, along with a CPU/VDU console. This has allowed it to build controllers capable of driving multiple hot runner systems using different voltages and loads within the same cabinet. PMS SYSTEMS EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.540081 Item 336 Plastics and Rubber Asia 9, No.55, Dec.1994, p.29 KRAUSS MAFFEI DEVELOPS NOVEL TECHNOLOGIES AND BEATS RECESSION Designs of new and improved injection moulding machines from Krauss-Maffei were demonstrated to customers from Taiwan and Singapore, where increased activity has compensated the company for losses in Europe. Details are included of machines for moulding recycled materials directly, for the production of multicolour mouldings, screws for marbled effects, and Duomeltor models which have two injection units mounted in parallel. KRAUSS-MAFFEI AG EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; SINGAPORE; TAIWAN; WESTERN EUROPE

Accession no.539776 Item 337 European Plastics News 22, No.1, Jan.1995, p.17 SOFT BUT STRONG Guyot H Reydel has developed a new car interior door handle produced using a combination of dual material and gas injection moulding technologies. The object is to produce a handle with a rigid and light core combined with a skin produced in an elastomeric material to give a soft touch. The part is injected on a Billion 140-tonne machine. The insert is gas injection moulded and then transferred to another cavity for over-moulding. The process is currently limited to relatively simple shapes and is suitable for series

95

References and Abstracts

of more than 350,000 parts a year. More than 30 combinations of materials have been tested. With PP (30% glass reinforced) some of the best results have been observed with PP-EPDM (Santoprene from AES). The advantage of this combination is that the two materials can be recycled together without compatibility problems. REYDEL SA; BILLION SA; GROSFILLEY EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; WESTERN EUROPE

Accession no.539115 Item 338 Injection Moulding: Advanced Technology for Optimisation of Operational Performance. Conference proceedings. Shawbury, 26th May 1994, paper 10. 831 LOST CORE MOULDING Yardley J Dunlop Automotive Composites UK Ltd. (Rapra Technology Ltd.) The injection moulding of high strength engineering composite plastic materials has now been developed to such a level that it is challenging conventional metal processes. Sophisticated electronic control of modern hydraulic systems can now guarantee a level of quality unheard of a few years ago. Aspects of the lost core moulding process described include coring materials, shape possibilities and applications. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.538942 Item 339 Plastics News(USA) 6, No.39, 28th Nov.1994, p.5 MULTIPLE RESINS, COLOURS USED IN LENS COVER Rowand R It is reported that Ford Motor has involved at least seven companies and about 30 people in a multi-colour, multimaterial injection moulding project for its new Mercury Mystique compact car. The vehicle, aimed at competing with imported cars, has a 2 1/3 lb rear lens made from Lexan polycarbonate, ABS and acrylic. The dramaticallystyled tail and back-up light cover, or applique lens, spans the width of the car. Details are given. FORD MOTOR CO. USA

Accession no.537036 Item 340 British Plastics and Rubber Oct.1994, p.28 PS & PE ARE MOULDED TOGETHER TO FORM RESEALABLE CLOSURE

96

Tetra Pak is making sealed, tamper-evident closures for its waxed card cartons. The Tetra Multi Spout has a PE collar and neck and a PS snap-closure. The PE neck forms the pouring spout, and when moulded, is closed off by a membrane. Over the top of the spout is moulded the PS cap, which has ridges and indentations causing the PE membrane to lock into it mechanically. Moulding of the closure was demonstrated at Ferromatik Milacron’s Malterdingen plant using a two material 100 tonne K100 machine running a turntable mould built by Foboha. This mould was laid out as an eight-cavity tool, indexing through four stations. Two stations were for injection, one for cooling and one allowed the mould to eject without adding to the cycle time. TETRA PAK LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.533848 Item 341 Advances in Polymer Technology 13, No.4, Winter 1994, p.305-14 PREDICTION OF SHRINKAGE BY DUAL KRIGING FOR INJECTION MOULDED PP PLAQUES Kamanayo G; Trochu F; Sanschagrin B Montreal,Ecole Polytechnique A new empirical method of predicting shrinkage in thermoplastic products, based on dual kriging interpolation is described. A theoretical validation was performed on a set of experimental measurements. Results for injection moulded PP plaques are compared with previous models based on regression. 32 refs. CANADA

Accession no.533561 Item 342 Kautchuk und Gummi Kunststoffe 47, No.9, Sept.1994, p.672-5 German LOWER PRODUCTION COSTS BY MULTICOMPONENT INJECTION MOULDING TECHNIQUES Jaroschek C Ferromatic Milacron The production costs of injection mouldings consist of approximately 50% material costs. It is shown that reductions are possible when non-visible parts of the product are made from recycled materials which exhibit good mechanical performance but have optical faults, e.g. colour variations. The Mono-Sandwich process, a new process for using recycled materials for the moulding’s core, is described. It is shown that the technique can reduce production costs by as much as 25%. 4 refs. EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WESTERN EUROPE

Accession no.531224

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Item 343 Plastics News(USA) 6, No.18, 4th July 1994, p.18 RECYCLING DRIVES USE OF COINJECTION MOULDING Goldsberry C Coinjection moulding has seen a growth in popularity in the USA. This detailed article highlights the reasons behind the increasing use of the process. These include: a reduction in piece-part cost, the ability to combine the properties of two different materials and the ability to use recycled materials as the core of a part. The article also details the advances in equipment for the process and applications for the finished products. BATTENFELD OF AMERICA INC.; GE PLASTICS USA

Accession no.525608 Item 344 Plastics News(USA) 6, No.18, 4th July 1994, p.1/26 MULTIMATERIAL MOULDING GAINS USE IN MULTIPLE APPLICATIONS Goldsberry C The article describes the growth in the use of multimaterial moulding, which is being driven by a need to get more than one function from a product, which in turn needs the properties that can only be obtained by using two materials. The article describes the widening fields of applications and cites examples of moulded products made from PP and thermoplastic elastomer. The article includes a description of the process. NYPRO INC.; CACO PACIFIC CORP.; CINCINNATI MILACRON INC.; MOLD MAKERS INC. USA

Accession no.525583 Item 345 Plastics and Rubber Weekly No.1548, 12th Aug.1994, p.19 THERE’S VALUE IN INTEGRATION Developments in the progress of multi-material moulding are reviewed. At a recent seminar, Billion UK displayed a small sample of products currently produced in Europe using multi-colour/multi-material moulding techniques. Billion is active in the development of two material techniques, and has recently launched its latest range of Herculite bi-material machines. Previous problems associated with the method are discussed, and improvements to provide an integrated approach to the application are examined. BILLION UK LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.522594

© Copyright 2002 Rapra Technology Limited

Item 346 Plastics and Rubber Weekly No.1543, 8th July 1994, p.9 BETTER BONDING IN CLOSED LOOP Closed loop injection control is an essential feature of a new range of 2C (two component) machines from 100 to 350 tonnes produced by Netstal. The company was approached by users of other types of machines, without closed loop, which were incurring unacceptable reject rates. Netstal responded by emphasising the importance of consistent melt flow and shrinkage rates attainable by use of this feature. A 175 tonne 2C machine has been demonstrated employing a mould by Weber to produce a dual hardness automotive part in PP and TPE. Trisa has 10 Netstal machines and makes toothbrush handles with the main stem in rigid PP and the handle in soft feel TPE. NETSTAL UK LTD. EUROPEAN COMMUNITY; EUROPEAN UNION; UK; WESTERN EUROPE

Accession no.522163 Item 347 Antec ’93. Conference Proceedings. New Orleans, La., 9th-13th May 1993, Vol.II, p.214954. 012 EVALUATION OF COINJECTION FLOW ANALYSIS SOFTWARE WITH FOAMED CORE MATERIAL Rastatter T P Pennsylvania,State University (SPE) Flow analysis software was used to study the effect of blowing agent on flow in the coinjection moulding of parts having a PS skin and a PS foam core, and to determine the feasibility of using such software to predict the filling of a coinjection moulded part. It was found that the blowing agent had a minimal effect on the filling of the part, and the software could be used to fairly accurately predict the filling pattern. AC TECHNOLOGY USA

Accession no.520579 Item 348 TPEL Retec ’93. Thermoplastic Elastomers: New Developments - Technology - Market Opportunities for the ’90s. Conference proceedings. Ft.Mitchell, Ky., 19th-20th Oct.1993, p.169-93. 6127 DECORATION AND DESIGN ENHANCEMENT THROUGH OVERMOULDING OF PEBAX THERMOPLASTIC ELASTOMERS Vasselin T; Conkey J Atochem Inc. (SPE,Miami Valley Section; SPE,Marketing & Management Div.; SPE,Thermoplastic Elastomers Special Interest Group)

97

References and Abstracts

The overmoulding of athletic footwear components, in particular for production of multi-colour shoe sole units and sole units with tailored mechanical performance, is discussed. The properties of polyether-block-amide(PEBA) thermoplastic elastomers are described, together with general injection moulding considerations for PEBA resin, injection moulding of inserts, overmoulding process, processing temp. window of the PEBA resins, shoe sole design parameters, and overmould gating. USA

Accession no.514206 Item 349 TPEL Retec ’93. Thermoplastic Elastomers: New Developments - Technology - Market Opportunities for the ’90s. Conference proceedings. Ft.Mitchell, Ky., 19th-20th Oct.1993, p.133-46. 6127 MULTI-COLOUR TECHNIQUE REVEALS NEW APPLICATIONS Richmond D Kloeckner & Co. (SPE,Miami Valley Section; SPE,Marketing & Management Div.; SPE,Thermoplastic Elastomers Special Interest Group) Multi-colour and multi-component injection moulding are discussed with reference to machine base and hydraulics, clamping unit, injection unit, mould concept for multicomponent moulding (rotary moulds, preform transfer, core-back method, melt-stop method), material concept for the multi-componennt technique (combinations of thermoplastics and thermoplastic elastomers), and injection moulding and assembly of incompatible materials. 10 refs. USA

Accession no.514204 Item 350 Plastics World 52, No.4, April 1994, p.14-5 COINJECTION OPENS DOOR FOR RECYCLED PET FOR FOODS Miller B Following the go-ahead from the US Food & Drug Administration, an injection moulding machine builder and a bottle producer have joined forces to develop the technology to use post-consumer recycled PETP for soft drinks bottles. The three stages of the moulding process, which ensures total encapsulation of a middle layer of recycled PETP by two outer layers of virgin PETP, are fully described. HUSKY INJECTION MOLDING SYSTEMS; CONTINENTAL PET TECHNOLOGIES; ACI PETALITE; US,FOOD & DRUG ADMINISTRATION AUSTRALIA; USA

Accession no.513692

98

Item 351 Plastics News(USA) 6, No.5, 4th April 1994, p.1/23 FORD TRIM PLANT TO GET 5-BARREL INJECTION UNIT Vernyi B Ford Motor is expecting to put North America’s first fivebarrel, multi-shot injection moulding machine into production within the next year. The company is purchasing the machine as part of a three-year, 65 million US dollars investment for its Plastic Trim and Products Division plant in Sandusky, Ohio. The expansion will include the purchase of a further 12-14 presses, and will create 30 jobs during 1994 and 100 more by 1997. Some company information is presented. FORD MOTOR CO.; KRAUSS-MAFFEI CORP. USA

Accession no.512022 Item 352 British Plastics and Rubber April 1994, p.22-3 FUSIBLE CORE TOOLING HAS POTENTIAL FOR EVERYBODY Morgan G Mining & Chemical Products Ltd. It is reported that, to those observing the technology, fusible coring must appear to have fallen short of the widespread adoption forecast for it in the early 1980s. Most of the progress has been in the automotive sector where, because of the nature of the industry, a great deal of valuable development work has remained secret or restrained by patent applications. The technology in the light of recent work aimed at widening the economic appeal of the process is described, including core casting, overmoulding, core melt out and low volume benefits. EUROPEAN COMMUNITY; UK; WESTERN EUROPE

Accession no.510986 Item 353 Injection Molding 2, No.2, Feb.1994, p.58 MULTI-INJECTION MOULDING SYSTEMS DEBUT Kirkland C It is reported that, in late summer 1993, Alvo Industries, a privately-held Canadian custom moulder serving consumer, telecommunications, medical and cosmetic markets, designed and built its own multi-injection moulding machinery systems to solve tough appearance and performance problems in a product for Northern Telecom. Since then, customer demand has forced Alvo to create a new company dedicated to designing and building its machinery systems, called Alvista Machinery. Details are given.

© Copyright 2002 Rapra Technology Limited

References and Abstracts

ALVO INDUSTRIES LTD.; ALVISTA MACHINERY INC. CANADA; USA

Accession no.508083 Item 354 Modern Plastics International 24, No.3, March 1994, p.44-6 MULTI-MATERIAL INJECTION SAVES TIME, WHILE CUTTING COSTS Mapleston P More plastics processors are turning to multi-material injection moulding as a way of increasing the added value of their products while keeping production costs down. Multi-material machines include units for coinjection and overmoulding. Examples of overmoulding applications are given including caps for jars, screwdriver handles, babies’ pacifiers and several automotive parts. Nozzle options and runner systems offered by machinery manufacturers are expanding coinjection and overmoulding choices, and new ways are being found to improve precision. WORLD

Accession no.507571 Item 355 Antec ’93. Conference Proceedings. New Orleans, La., 9th-13th May 1993, Vol.I, p.82-6. 012 NUMERICAL SIMULATIONS AND EXPERIMENTAL STUDIES OF THE COINJECTION MOULDING PROCESS Chen S C; Hsu K F; Hsu K S; Jeng M C Chung Yuan University (SPE) Experimental studies of the coinjection moulding process were performed in order to observe the two-phase polymer melt flow during mould filling. The interface shape at the core-skin boundary and the fountain flow regions for both melt fronts were investigated. A simple algorithm based on the residual time approach was used to simulate the core and skin melt front advancement during the mould filling stage. 7 refs. TAIWAN; USA

Accession no.507312 Item 356 Plastics Technology 40, No.2, Feb.1994, p.21/3 CLOSE-UP LOOK AT A LOST-CORE MANUFACTURING CELL Naitove M H This article takes a close-up look at the lost-core process with its lost-core manufacturing cell, at Siemens Automotive LP plant in Ontario. The automated process

© Copyright 2002 Rapra Technology Limited

is described in detail, including difficulties encountered putting the lost-core system into production, and Siemen’s plans for the future. SIEMENS AUTOMOTIVE L.P.; DUPONT CO.; KLOCKNER FERROMATIK DESMA; KLOCKNER DESMA; FTF; BASF CORP.; CHRYSLER CANADA; EUROPEAN COMMUNITY; GERMANY; USA; WESTERN EUROPE

Accession no.504099 Item 357 Plastics News(USA) 5, No.35, 25th Oct.1993, p.7 HANDY & HARMAN FORGES TECHNOLOGY ALLIANCE Vernyi B Handy & Harman has formed a technical and a commercial alliance with MGI-Coutier, a French automotive supplier, as part of its efforts to launch lostcore injection moulding as a full production process. Handy & Harman, manufacturer of fuel lines, is to make plastic fuel rails and engine manifolds. HANDY & HARMAN AUTOMOTIVE GROUP INC.; MGI-COUTIER; FORD MOTOR CO.; INNOVATIONS IN COMPOSITES INC. EUROPEAN COMMUNITY; FRANCE; USA; WESTERN EUROPE

Accession no.500571 Item 358 Muanyag es Gumi 30, No.9, 1993, p.227-8 Hungarian INJECTION OF MULTI-COMPONENT MATERIALS Steinbichler G; Dunai A Engel Vertriebsges mbH; Froccstechnika Kft A brief review describes the use of multi-component material injection moulding for the production of sport, domestic and fashion articles. The omission of welding, riveting and other processes results in a reduction in costs. The authors describe the expected adhesion properties of combinations of plastics during multicomponent injection moulding and demonstrate the principle of the slip-plate process. Articles from this journal can be requested for translation by subscribers to the Rapra produced International Polymer Science and Technology. EASTERN EUROPE; HUNGARY

Accession no.498517 Item 359 Advanced Materials Newsletter 15, No.19, 11th Oct.1993, p.1-2 METALLIC CORE TECHNOLOGY IS KEY TO ONE-PIECE HOLLOW PLASTIC PARTS

99

References and Abstracts

This article supplies details of the metallic core technology developed by Electrovert-MDD. The system uses low melting temperature alloys to make cores by a low pressure injection process. The article provides examples of effective applications of the system in the automotive industry. ELECTROVERT-MDD USA

Accession no.497557 Item 360 British Plastics and Rubber Nov.1993, p.21 MULTI-LAYER MOULDING GIVES BETTER BLENDS THAN BLENDING A process for injection moulding dissimilar materials in a multi-layer structure containing up to 2,000 plies has been developed and offered for licence by Dow Plastics. Lamellar Injection Moulding is an offshoot of the coextrusion technology used by the company to produce its Polymeric Reflective Material. The process uses a feedblock between the barrels and nozzle of a multicomponent machine to split a three-layer (or five-layer if a third, tie-layer injection unit is used) ABA melt stream into four streams, ‘flatten’ each stream and stack them into a nine-layer stream, and then repeat the process several times. Details are given. DOW PLASTICS EUROPEAN COMMUNITY; UK; WESTERN EUROPE

Accession no.496893 Item 361 Asian Plastics News July 1993, p.13 MULTI-COMPONENT TECHNIQUES Smith C Examples are given of applications where multicomponent injection moulding techniques can provide benefits in quality and parts integration which outweigh the additional complexities of the technique. WESTERN EUROPE; WESTERN EUROPE-GENERAL

Accession no.494991 Item 362 Modern Plastics International 23, No.9, Sept.1993, p.14/8 COINJECTION PRESS MAKES SANDWICH MOULDING SIMPLE Mapleston P The Mono Sandwich injection moulding press from Kloeckner Ferromatik Desma should, it is claimed, simplify production of parts with core and skin layers in different materials. The system employs and auxiliary injection unit that pushes a skin material into a primary injection unit, which holds material for the core layer. Details are given.

100

KLOECKNER FERROMATIK DESMA GMBH EUROPEAN COMMUNITY; GERMANY; WESTERN EUROPE

Accession no.492961 Item 363 Industria della Gomma 37, No.6, June 1993, p.39-41 Italian RUBBER, METAL AND PLASTICS LIVE TOGETHER HAPPILY Machinery developed by MIR SpA for coinjection and insert moulding is described. Particular material combinations examined include metal/polyamide/PU, liquid silicone rubber with thermoplastics such as polycarbonate, and high-impact PS with thermoplastic elastomers. MIR SPA EUROPEAN COMMUNITY; ITALY; WESTERN EUROPE

Accession no.491554 Item 364 Materials Edge No.50, July 1993, p.7 WASTE PLASTICS - GETTING TO THE CORE Smith G The use is described of controlled dual injection moulding of mixed plastics waste, as a major alternative to waste separation or incineration techniques which may prove costly. Work carried out at the Advanced Technology Centre in collaboration with Rover is using plastics regrind as a core filler for a dual injection moulded sandwich component. ADVANCED TECHNOLOGY CENTRE; ROVER GROUP PLC EUROPEAN COMMUNITY; UK; WESTERN EUROPE

Accession no.488823 Item 365 Kunststoffe German Plastics 83, No.6, June 1993, p.3-5 EXPANDED APPLICATION AREAS FOR MULTICOMPONENT INJECTION MOULDING Kraft H Kloeckner Ferromatik Desma GmbH The production of multicolour and multicomponent injection mouldings is well established. Today material combinations and an increasingly perfected mould technology permit the manufacture of complex functional elements. The processing of thermoplastics of different hardness and incompatible materials leads to a substantial increase in the use of multicomponent parts in the engineering sector, e.g. in the automotive industry. 5 refs. (Translation of Kunststoffe, 83, No.6, 1993, p.429/33) EUROPEAN COMMUNITY; GERMANY; WESTERN EUROPE

Accession no.487345

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Item 366 Plastics News(USA) 5, No.13, 24th May 1993, p.7 COINJECTION MOULDER CO-MACK EXPANDING Goldsberry C

and Design Competition for the most innovative product of the conference. Details are given of the long carbon fibre reinforced nylon wheel manufactured by lost-core technology, and also other awards in other categories are briefly described. INNOVATIONS IN COMPOSITES INC.

Co-Mack Technology, whose innovative application of the coinjection moulding process has helped it claim several new product design awards recently, is reported to need to expand to keep pace with business. The company has operated its eight-press facility 24 hours a day, seven days a week, for all but two Sundays since the beginning of 1993. Some company information is presented. CO-MACK TECHNOLOGY INC.

USA

USA

Accession no.485013 Item 367 Plastverarbeiter 44, No.5, 1993, p.26-9 German FUTURE OF LOST-CORE TECHNOLOGY HAS ONLY JUST BEGUN Lost core technology is providing a solution to the problem of demoulding injection moulded hollow parts with complex interior geometries. Two lost core technology lines at Klockner Ferromatik Desma, which have this capability, are described. KLOCKNER FERROMATIK DESMA EUROPEAN COMMUNITY; GERMANY; WESTERN EUROPE

Accession no.482732 Item 368 PV International Plastics Magazine 4, No.1, May 1993, p.60-1 COMPLETELY MOBILE AIR VENTS IN EVERY CYCLE A multi-component injection moulding technique has been developed by Kloeckner Ferromatik Desma with collaboration on mould design with Fickenscher. Details are given of the use of the mould by VW to produce air vents for the new Golf cars. KLOECKNER FERROMATIK DESMA GMBH; FICKENSCHER GMBH EUROPEAN COMMUNITY; GERMANY; WESTERN EUROPE

Accession no.482099

Accession no.481286 Item 370 Plastics World 51, No.5, May 1993, p.16 TWO-SHELL OVERMOULDING CHALLENGES LOST-CORE Miller B Two-shell overmoulding, a variation of encapsulation, is reported to offer a low-cost alternative to the lost-core process for injection moulding air intake manifolds and other hollow parts. Developed by Bayer in Germany and patented in the USA, the overmoulding technique is being introduced to the USA by Miles. The hollow part is basically moulded as two halves with mating flanges which are assembled, then the assembly is overmoulded to produce the one-piece component. Details are given. BAYER AG; MILES INC. EUROPEAN COMMUNITY; GERMANY; WESTERN EUROPE

Accession no.478098 Item 371 European Plastics News 20, No.5, May 1993, p.26 LOST CORE FINDS WIDER APPEAL Smith C Lost core moulding has been most widely used in the automotive sector for the production of plastics inlet manifolds, where weight savings and smooth internal bores are major advantages. A Danish company is using the technique to produce thermostat housings and water pump parts for heating systems. The recently introduced Ford Zeta manifold uses two cores which interlock precisely to prevent any internal flash. Klockner Ferromatik Desma and Electrovert-Fry are the leading hardware suppliers. KLOCKNER FERROMATIK DESMA; ELECTROVERT WESTERN EUROPE; WESTERN EUROPE-GENERAL

Accession no.476878

Item 369 Plastics News(USA) 5, No.10, 3rd May 1993, p.22 LOST-CORE MOULDED WHEEL TAKES TOP PRIZE Goldsberry C

Item 372 European Plastics News 20, No.5, May 1993, p.21-2 MULTI-COMPONENT SOLUTIONS Smith C

A three-spoke injection moulded bicycle wheel took awards at the Structural Plastics Conference New Product

The latest developments in multi-component injection moulding are outlined. Frenach is producing a six-colour

© Copyright 2002 Rapra Technology Limited

101

References and Abstracts

keypad assembly using a six-injection unit moulding machine from MIR. Yorka has opted for a manufacturing cell from Mannesmann Demag comprising one twocomponent machine and one standard single-component injection machine linked with CNC robotics for the production of its latest rear light lens assembly. Klockner Ferromatik Desma has applied the technique of moulding with non-bonding materials to produce an automotive air vent which incorporates moulded-in movable joints. Engel has supplied a two-component system built around tiebarless technology for production of step ladder feet in a combination of rigid and elastic materials. ENGEL GMBH; KLOCKNER FERROMATIK DESMA; MANNESMANN DEMAG; MIR SPA WESTERN EUROPE; WESTERN EUROPE-GENERAL

Accession no.476876 Item 373 Plastverarbeiter 44, No.2, 1993, p.60-1 German COMPLETELY MOBILE AIR VENTS Multi-component injection moulding is used to produce air vents for the new Volkswagen Golf. No costly assembling is required. The mould was developed in collaboration with Fickenscher. KLOECKNER FERROMATIK DESMA GMBH; FICKENSCHER EUROPEAN COMMUNITY; GERMANY; WESTERN EUROPE

Accession no.474534 Item 374 Modern Plastics International 23,No.1,Jan.1993,p.31-2 LOST-CORE MOULDING OFFERS A ROUTE TO HOLLOW PARTS WITH COMPLEX GEOMETRIES Sattler E R BASF Corp. Lost-core injection moulding is gaining wide acceptance by the automotive industry as a highly efficient process for creating lightweight and complex hollow parts. This article describes how an air intake manifold is produced from glass fibre-reinforced nylon 66, with a core cast using a tin/bismuth alloy, which melts at a low temperature. The three stages of the process, namely, casting the metal alloy core, injection moulding the manifold and melting out the alloy core are outlined, together with the properties of the material used. USA

Accession no.466505 Item 375 British Plastics and Rubber No.3,March 1992,p.4/11

102

MULTI-MATERIAL MOULDING OPENS DOORS TO DESIGN AND DEVELOPMENT Sonnery M BILLION UK LTD. This article reviews multi-material moulding techniques including sandwich moulding with only one material visible, more than one material visible in a ‘random’ pattern, and insert moulding where several materials are visible with a defined interface between materials. Any process using two different materials requires an injection moulding machine fitted with two injection units and a material distribution system between the two barrels. Two Billion multi-colour machines have been installed at Wipec to mould rear light lenses for Ford. EUROPEAN COMMUNITY; UK; WESTERN EUROPE

Accession no.446376 Item 376 British Plastics and Rubber No.3,March 1992,p.11 BIG BATTENFELD MAKES MULTICOMPONENT TV PARTS The largest Battenfeld multi-component machine in the UK has been commissioned at Otford Specialised Mouldings to produce multi-component television parts. The 1,250 tonne machine is the fourth of this make at the plant, all of which also have automatic mould changing facilities. The machines can also be used for conventional moulding or structural foam.This abstract includes all the information contained in the original article. OTFORD SPECIALISED MOULDINGS EUROPEAN COMMUNITY; UK; WESTERN EUROPE

Accession no.446233 Item 377 Eureka 11,No.4,April 1991,p.28/31 SOLUBLE CORES SMASH MOULDING LIMITATIONS Shelley T Belland has developed a copolymer which dissolves in hot water and represents a major breakthrough in lost core moulding. Developed for the production of complex aerospace components, it can be overmoulded with conventional plastics at temperatures of up to around 320C. The material is a copolymer of acrylic acid and acrylic ester with reactive carboxyl groups hanging off the polymer backbone. The material can be recovered from solution and used again, and can be moulded on conventional equipment. The soluble plastic is also very suitable for use as a former on which filaments can be wound. BELLAND AG SWITZERLAND; WESTERN EUROPE

Accession no.422496

© Copyright 2002 Rapra Technology Limited

References and Abstracts

Item 378 Plaste und Kautschuk 34,No.7,July 1987,p.267-9 German PRODUCTION OF HIGH-QUALITY MOULDINGS FROM RECYCLED MATERIALS BY MEANS OF THE MULTI-COMPONENT INJECTION MOULDING PROCESS Eckardt H BATTENFELD MASCHINENFABRIKEN GMBH The multi-component injection moulding process, which involves the manufacture of products consisting of a core material and an outer skin, is discussed with reference to using recycled plastics as the core material. Machine and processing technology are explained and details given on the economics of this process. Application possibilities are considered. WEST GERMANY

Accession no.351820 Item 379 Plastics and Rubber Weekly No.1131,29th March 1986,p.14 SANDWICH MOULDING USED IN MAJOR AREAS OF INDUSTRY Eckardt H BATTENFELD MASCHINENFABRIK GMBH

Item 380 Plastics and Rubber Weekly No.1109,12th Oct.1985,p.8-9 LOW COST EMI SHIELDING USING SANDWICH MOULDING A discussion is presented on how sandwich moulding is being used to produce high specification, low cost electromagnetic radiation (EMI) shielding components. Several methods of producing EMI shields on plastic mouldings are reviewed. The most cost effective way of producing a conductive polymeric compound is by the incorporation of carbon black. The disadvantages of this, and the way they are overcome by using the twocomponent moulding technique is explained. Mention is made of specific Cabelec compounds produced by Cabot to take advantage of the process, while giving the required EMI performance. Data is provided showing a comparison of moulding processes and the relative cost of adding EMI screen. CABOT CORP. WORLD

Accession no.302184

Details are given of multi-component injection moulding which uses one material for the outer skin and another to form the core. The various materials that can be used, and the applications of the process are discussed. A table is presented of the adhesion characteristics of different materials. Accession no.309071

© Copyright 2002 Rapra Technology Limited

103

References and Abstracts

104

© Copyright 2002 Rapra Technology Limited

Subject Index

Subject Index A ABRASION RESISTANCE, 42 51 159 266 271 ACCURACY, 24 127 254 334 347 ACRYLATE COPOLYMER, 377 ACRYLIC ESTER COPOLYMER, 377 ACRYLIC POLYMER, 179 200 213 282 ACRYLONITRILE-BUTADIENESTYRENE, 4 38 42 50 56 86 88 89 92 98 105 137 149 165 170 174 179 194 199 204 211 212 213 226 238 253 259 260 265 266 269 285 293 306 309 318 328 332 345 354 364 372 379 ACRYLONITRILE-STYRENEACRYLATE TERPOLYMER, 38 89 99 199 265 266 ACRYLONITRILE-STYRENEACRYLIC ESTER TERPOLYMER, 38 89 99 199 265 266 ADDED VALUE, 101 273 ADDITIVE, 1 2 11 16 75 80 151 164 217 218 241 244 258 282 290 310 328 347 ADHESION, 5 9 16 17 28 39 43 47 51 65 81 90 108 114 115 121 132 147 151 153 169 196 199 203 211 218 224 237 246 253 261 265 266 281 300 307 320 325 337 358 365 379 ADHESION PROMOTER, 218 307 ADHESION-MODIFIED, 237 ADHESIVE, 6 135 377 ADHESIVE STRENGTH, 5 39 47 114 AEROSPACE APPLICATION, 256 304 377 AESTHETIC, 2 17 26 41 51 52 75 AGEING, 266 AIR BAG, 17 266 AIR BARRIER, 182 AIR DISTRIBUTOR, 80 AIR DUCT, 377 AIR EJECTION, 36 AIR INTAKE SYSTEM, 5 114 AIR-INTAKE MANIFOLD, 158 254 256 370 AIR RELEASE, 1 AIR VENT, 192 228 354 368 372 373

ALLOY, 76 356 374 ALUMINIUM, 11 17 218 374 AMIDE COPOLYMER, 348 AMIDE-ETHER COPOLYMER, 337 AMORPHOUS, 89 290 313 ANALYSIS, 16 83 93 128 193 264 282 290 310 313 328 332 333 334 347 ANNEALING, 132 328 ANTENNA, 137 APPEARANCE, 4 15 168 262 ARMATURE, 83 ARMOUR, 193 ASSEMBLY, 12 81 127 167 198 228 237 302 305 318 329 349 AUTOMATION, 2 5 18 19 29 35 43 51 55 57 67 73 74 75 80 81 98 101 122 126 134 140 141 142 157 164 167 194 199 200 204 211 215 224 234 240 244 245 254 269 276 293 304 305 312 329 363 374 AUTOMOTIVE APPLICATION, 1 2 5 6 11 16 17 20 24 28 29 41 52 57 62 70 71 75 78 80 81 82 85 103 105 108 109 112 114 118 119 121 125 131 132 134 135 142 145 147 149 151 158 162 163 165 171 175 191 192 196 199 204 209 211 212 213 216 218 221 223 224 228 230 232 234 236 238 240 241 242 246 247 253 257 261 262 265 266 275 276 284 292 298 299 302 303 304 305 307 312 314 316 324 325 329 330 331 337 339 344 346 351 352 354 357 359 360 365 368 370 371 372 373 374 375 379 AWARD, 48 168

B BACK INJECTION MOULDING, 17 BACKMOULDING, 34 53 BARREL, 15 23 252 258 285 BARRIER, 91 BARRIER LAYER, 126 145 152 191 212 231 BARRIER PACKAGING, 126 135 322 BARRIER PROPERTIES, 41 126 135 144 149 182 186 218 322

© Copyright 2002 Rapra Technology Limited

BARRIER SCREW, 19 41 75 BATHROOM FITTING, 324 BATTERY CASE, 296 325 BEER BOTTLE, 135 144 163 182 186 BELLOWS, 206 BELT, 84 BICYCLE WHEEL, 256 304 357 369 BIREFRINGENCE, 187 290 BLEND, 9 11 13 14 78 85 89 98 141 182 194 199 211 212 214 260 263 265 266 285 290 306 324 325 328 332 349 360 364 BLOW MOULDING, 30 41 111 135 186 212 286 298 308 330 BLOWING AGENT, 2 44 48 76 99 150 195 244 252 282 347 BODY PANEL, 11 48 80 204 324 BOND STRENGTH, 9 42 45 62 64 68 87 89 90 95 108 121 128 138 169 196 240 263 281 295 299 302 BONDING, 6 42 43 45 61 81 82 89 90 114 118 128 132 147 169 179 196 200 295 307 345 346 377 BONDING AGENT, 218 BONNET, 48 BOOT, 28 BOSS, 56 155 332 BOTTLE, 41 87 111 126 135 144 145 152 163 182 186 212 231 274 336 354 BOUNDARY CONDITION, 290 334 BOUNDARY LAYER, 196 BRASSIERE, 79 83 BREATHABILITY, 51 BRITTLE FAILURE, 313 BRUSH, 141 194 195 259 BUCKET, 249 265 BUILDING APPLICATION, 16 225 266 324 BUMPER, 2 11 70 135 199 212 221 238 239 242 247 257 262 270 275 292 294 324 BUSINESS MACHINE, 28 56 77 238 265 343 BUTADIENE-ACRYLONITRILE COPOLYMER, 81 114 146 151 199 200 BUTENE COPOLYMER, 282 BUTTON, 165

105

Subject Index

C CABLE, 6 62 245 CABLE CONNECTOR, 200 245 CAMERA, 59 222 229 CAP, 156 340 CAPACITY, 3 194 230 275 291 CAR, 1 2 11 16 17 28 29 41 52 75 80 135 142 151 199 204 211 218 223 224 230 238 247 253 266 276 316 CARBON BLACK, 151 218 380 CARBON DIOXIDE, 2 16 CARBON FIBRE-REINFORCED PLASTIC, 310 369 CARBONATED BEVERAGE BOTTLE, 126 135 182 CARBOXYLATED RUBBER, 114 151 CAROUSEL SYSTEM, 141 226 259 CARTON, 137 155 340 CARTRIDGE, 137 CASE HISTORY, 44 229 CASING, 224 238 377 380 CASTING, 51 312 352 CATHETER, 200 CAVITY, 4 12 24 56 81 86 91 160 161 162 171 195 216 287 CAVITY FILLING, 44 CAVITY PRESSURE, 44 49 218 298 332 334 CELLULAR MATERIAL, 2 7 15 16 34 35 51 53 75 76 99 101 119 126 135 140 141 145 150 195 204 211 218 224 244 252 253 260 265 282 379 CERAMIC, 101 CHAIR, 99 244 259 283 324 CHEMICAL MODIFICATION, 115 116 CHEMICAL PROPERTIES, 12 41 62 63 115 139 159 253 266 CHEMICAL RESISTANCE, 12 41 42 62 63 108 115 139 159 200 253 266 374 CHIP, 269 CHLORINATED POLYETHYLENE, 199 CLAMP FORCE, 1 2 3 4 10 11 12 17 18 19 23 24 27 29 35 36 51 52 55 57 60 75 76 77 83 84 86 87 88 98 99 101 104 106 127 133 137 140 141 142 149 150 155 160 163 164 165 167 186 191 192 194 199 204 207 209 211 212 216 217 218 222 224 226 227 233 238 240 241 242

106

244 247 249 252 253 254 259 260 268 269 283 287 291 292 293 297 305 306 316 317 318 326 327 337 340 346 354 372 CLAMPING UNIT, 18 27 36 55 75 88 97 99 140 141 153 164 194 199 211 224 226 238 244 247 253 283 288 291 349 CLARITY, 59 103 115 225 CLEAN ROOM, 19 204 CLOSED LOOP, 130 350 CLOSED LOOP CONTROL, 75 101 140 152 194 224 229 244 335 346 CLOSED MOULD, 87 211 CLOSURE, 10 19 85 87 109 137 141 155 156 160 182 211 336 340 354 CLOTHING, 79 83 CLUTCH, 23 CO-MOULDING, 42 108 109 122 249 260 307 COATING, 6 82 107 112 116 144 246 286 COEFFICIENT OF FRICTION, 329 COEXTRUDER, 288 COEXTRUSION, 16 42 85 89 266 282 328 330 COHESION, 151 COINJECTION, 34 36 48 91 109 175 179 186 191 212 226 231 239 241 258 259 265 270 283 287 291 308 325 327 331 354 COINJECTION BLOW MOULDING, 135 COINJECTION MOULDING, 7 12 15 16 17 18 23 25 27 28 30 41 44 49 50 53 60 66 70 71 75 76 77 78 81 85 88 89 92 93 100 103 105 117 126 135 136 140 141 142 144 145 146 152 157 159 162 163 164 165 168 170 171 173 174 177 182 187 188 193 195 205 211 214 215 216 218 221 237 238 240 242 243 244 247 251 252 253 255 257 262 266 268 272 273 278 282 286 290 294 299 300 303 309 319 322 324 333 343 347 350 355 358 362 363 364 366 COINJECTION RESIN TRANSFER MOULDING, 193 COLD FEED, 135 COLD MOULD, 290 COLD RUNNER, 55 61 101 126 146 159 216 307 325 COLLAPSIBLE CORE, 210

COLOUR, 1 15 18 24 28 51 63 76 77 80 84 126 135 164 194 198 203 225 238 253 270 271 299 342 COLOUR CHANGING, 1 55 COLOUR MATCHING, 4 26 COLOURANT, 308 COLOURED, 222 COLOURING, 88 194 266 COMFORT, 51 80 COMMERCIAL INFORMATION, 3 73 76 77 81 82 104 107 108 155 166 168 174 175 180 183 194 200 206 222 232 272 275 351 353 357 366 COMPATIBILISER, 25 42 177 246 COMPATIBILITY, 25 65 146 163 179 193 203 207 265 281 285 302 324 COMPOSITE, 4 12 15 33 40 48 66 74 75 79 97 117 132 136 158 164 168 173 190 191 193 196 199 201 204 205 211 214 218 250 252 253 263 265 277 282 286 290 291 298 306 307 310 315 316 317 325 328 337 359 362 369 374 377 COMPOUND, 11 12 211 253 COMPOUNDING, 35 203 COMPRESSION, 51 330 COMPRESSION MOULD, 286 COMPRESSION MOULDING, 7 51 173 196 205 236 240 251 COMPRESSION SET, 42 63 115 153 266 COMPUTER AIDED DESIGN, 58 77 114 127 129 186 191 194 285 296 306 315 325 326 COMPUTER AIDED ENGINEERING, 49 77 205 355 COMPUTER AIDED MANUFACTURE, 77 296 COMPUTER CONTROL, 2 18 29 43 51 67 74 75 101 122 126 140 142 157 194 199 211 215 224 244 254 269 276 316 317 346 COMPUTER MOUSE, 206 COMPUTER SIMULATION, 1 17 49 93 114 151 172 181 256 290 296 298 326 333 334 347 355 CONDOM, 318 CONDUCTIVE FIBRE, 149 CONDUCTIVE FILLER, 380 CONDUCTIVE PLASTIC, 217 220 265 380 CONDUCTIVE RUBBER, 245

© Copyright 2002 Rapra Technology Limited

Subject Index

363 CONNECTOR, 38 108 147 150 CONSUMER GOODS, 29 41 165 175 CONTACT ANGLE, 90 115 CONTAINER, 2 19 41 111 126 135 144 182 204 238 287 CONTROL EQUIPMENT, 24 35 67 149 150 159 171 186 205 217 222 228 258 260 265 269 274 293 309 316 317 326 332 335 336 372 CONTROL SYSTEM, 1 2 17 18 29 51 55 74 75 101 123 126 135 140 142 189 194 199 201 211 215 224 238 244 271 276 316 317 332 336 CONVEYOR BELT, 84 COOKWARE, 14 COOLING, 1 2 12 17 44 51 62 67 75 76 98 107 128 137 141 142 151 157 180 199 211 223 226 236 244 279 281 289 290 298 306 310 313 316 318 340 363 COOLING TIME, 2 17 51 72 128 141 151 211 244 249 259 313 332 COPOLYESTER, 90 194 COPPER, 40 CORE, 15 17 18 23 28 41 78 85 100 105 107 126 135 136 140 141 162 163 164 204 211 217 218 224 231 240 252 253 256 262 270 271 290 298 310 313 324 330 333 337 342 347 352 354 355 356 359 364 375 378 COSMETICS, 2 28 126 135 204 COST, 4 10 15 17 28 29 41 42 43 51 52 56 58 71 76 80 81 85 88 94 98 99 105 116 118 127 130 131 134 141 142 144 146 153 155 158 159 160 162 165 167 171 176 180 197 204 206 208 209 210 217 218 219 227 228 231 237 239 241 242 245 252 255 256 259 265 270 272 287 293 295 298 303 307 311 312 321 324 325 343 344 354 358 359 375 378 380 COST ANALYSIS, 23 115 176 296 325 COUNTERFLOW INJECTION MOULDING, 251 COUPLING AGENT, 16 132 CRATE, 238 CREEP, 39 85 329 CROSSLINKING, 12 115 132 245 CRYSTALLINITY, 93 247 290 310

313 CUP, 150 260 264 CURE TEMPERATURE, 5 108 114 151 CURE TIME, 43 51 55 108 114 115 121 151 CURING, 5 6 12 115 159 189 193 225 282 363 CUSTOM MOULDING, 26 82 208 285 306 CYCLE TIME, 1 2 5 10 12 17 19 21 24 39 52 65 75 76 86 87 88 98 99 101 104 107 108 114 115 127 137 140 141 142 150 151 155 163 168 176 191 194 206 211 219 226 228 238 241 247 252 253 259 260 268 269 276 283 289 293 296 297 306 325 326 327 332 340 346 354 372 374

D DART DROP, 328 DASHBOARD, 316 331 DAYLIGHT MOULD, 209 DECORATION, 11 19 141 244 305 311 316 317 330 346 348 DEFECT, 28 44 56 141 218 310 342 DEFORMATION, 49 151 290 DEGRADATION, 245 266 DELAMINATION, 120 310 DEMAND, 10 12 186 198 203 229 269 292 324 343 354 DEMOULD, 110 271 277 363 367 DEMOULDING, 1 2 3 18 19 27 43 55 75 88 129 150 164 194 199 204 210 211 224 227 238 254 DENSITY, 11 51 76 110 115 282 283 286 310 334 DENTAL APPLICATION, 124 DEPTH PROFILING, 282 DESIGN, 4 5 11 12 15 20 21 30 37 39 40 48 54 58 59 61 63 64 72 77 83 84 98 105 106 109 112 117 124 129 130 143 145 149 151 153 159 168 171 178 188 190 194 198 202 206 219 221 227 228 230 231 235 236 256 257 261 263 285 304 309 321 323 339 348 366 DIE, 288 291 DIE ROTARY INJECTION MOULDING, 158 DIELECTRIC PROPERTIES, 16 DIMENSION, 1 17 148 238 244 286 328 332 334

© Copyright 2002 Rapra Technology Limited

DIMENSIONAL CONTROL, 346 DIMENSIONAL STABILITY, 28 141 324 DIRECT ADHESION, 16 DIRECT INJECTION, 51 97 148 DISSOLUTION, 116 DISTORTION RESISTANCE, 256 DISTRIBUTOR BLOCK, 1 148 223 277 DOMESTIC EQUIPMENT, 2 24 28 52 104 105 118 119 121 125 136 175 203 204 212 252 266 301 358 372 DOOR, 99 200 218 238 247 256 DOOR HANDLE, 136 163 175 239 252 265 337 DOOR PANEL, 82 218 238 247 DOUBLE DAYLIGHT MOULD, 35 DOUBLE FEED, 164 DOUBLE TOGGLE, 27 DOWNTIME, 162 244 DRILL, 238 DRINKING VESSEL, 150 260 264 DRIVE, 3 27 88 97 DRUG PACKAGING, 21 126 135 204 DUAL DENSITY, 51 110 DUAL HARDNESS, 104 106 131 149 150 159 241 260 284 346 DUAL INJECTION MOULDING, 7 12 15 16 17 18 23 25 27 28 30 41 44 60 66 70 71 75 76 77 78 81 85 88 89 100 103 105 117 126 135 136 140 141 142 144 145 146 152 157 159 162 163 164 165 168 171 173 174 177 182 187 188 193 205 211 214 215 216 218 221 237 238 240 242 243 244 247 251 252 253 255 257 262 266 272 273 278 282 DURABILITY, 103 112 193 207 307 DWELL TIME, 276 277

E ECONOMIC INFORMATION, 3 6 10 12 76 81 85 104 108 132 133 167 182 183 186 191 194 198 200 203 204 229 269 EDGE EFFECT, 333 EJECTION, 3 18 27 88 155 166 180 277 ELECTRIC, 3 35 57 99 104 150 260 297 ELECTRIC CAR, 165

107

Subject Index

ELECTRIC IRON, 266 ELECTRIC KETTLE, 306 ELECTRIC MOTOR, 27 88 97 101 137 140 238 ELECTRIC MOULDING TECHNOLOGY, 3 52 88 142 ELECTRIC RAZOR, 17 ELECTRICAL APPLICATION, 2 28 52 104 141 204 218 237 253 277 301 307 329 372 375 376 ELECTRICAL CONDUCTIVITY, 116 138 220 241 363 380 ELECTRICAL CONNECTOR, 108 147 150 ELECTRICAL DISCHARGE MACHINING, 127 191 ELECTRICAL INSULATION, 146 245 253 307 ELECTRICAL PROPERTIES, 16 115 245 253 363 ELECTRICAL SWITCH, 213 277 ELECTROMAGNETIC SHIELD, 149 265 380 ELECTRONIC APPLICATION, 2 6 38 52 75 105 116 125 163 204 220 224 305 326 331 363 380 ELECTRONIC EQUIPMENT, 138 237 ENCAPSULATION, 6 78 168 239 343 ENERGY CONSUMPTION, 3 11 24 75 80 88 171 204 223 238 249 276 287 293 297 ENGINE, 356 ENGINE MOUNTING, 62 ENGINEERING, 49 77 90 365 ENGINEERING APPLICATION, 2 17 18 43 89 90 194 199 203 204 211 218 237 253 257 265 266 270 277 310 364 365 ENGINEERING PLASTIC, 2 17 18 42 43 89 115 147 194 199 203 204 211 217 218 237 253 257 265 266 270 277 310 EPOXY RESIN, 282 310 EQUIPMENT, 15 84 86 129 130 154 162 168 182 209 210 216 228 275 304 343 348 349 359 ERGONOMIC, 11 18 26 52 89 101 ETHYLENE ACRYLIC RUBBER, 200 ETHYLENE-PROPYLENEDIENE TERPOLYMER, 42 85 194 199 200 223 241 245 284 325 337 ETHYLENE-VINYL ACETATE COPOLYMER, 30 51 76 141 199 266

108

ETHYLENE-VINYL ALCOHOL COPOLYMER, 30 126 135 149 182 186 218 270 322 EXHAUST SYSTEM, 62 108 EXPORT, 191 318 336 EXTERNAL GAS MOULDING, 97 EXTRUDER, 16 154 227 239 288 EXTRUSION, 6 16 85 99 166 212 266 275 282 288 341

F FABRIC, 17 51 247 251 FAILURE, 76 117 151 218 313 FAMILY MOULD, 17 FASCIA, 70 242 257 324 FASTENER, 26 56 179 329 FEEDING, 15 18 19 51 104 135 258 284 329 FENDER, 48 FIBRE, 4 40 136 194 290 298 316 317 FIBRE-REINFORCED PLASTIC, 35 45 47 89 193 FIFO, 43 55 FILLED, 149 199 201 204 206 211 253 282 310 360 FILLER, 1 11 16 75 76 114 138 151 162 164 218 220 226 241 244 245 282 290 310 328 364 379 380 FILLER CONTENT, 89 115 164 259 328 FILLING, 4 15 40 56 FILM, 11 17 234 244 316 317 FINISHING, 82 105 305 306 FINITE ELEMENT ANALYSIS, 83 93 128 193 264 315 334 FIVE-LAYER, 126 FLAMMABILITY, 193 266 FLASH, 85 332 346 FLASH REMOVAL, 140 204 FLASHLESS, 17 55 FLAW, 44 56 FLEXIBILITY, 5 39 47 114 115 120 121 138 139 151 199 204 218 223 237 253 281 287 306 365 FLEXURAL PROPERTIES, 33 112 117 120 149 151 173 196 214 218 324 328 329 334 FLOW, 1 4 8 14 15 17 24 50 56 92 100 126 135 170 189 193 211 248 278 280 282 290 298 310 316 317 332 333 334 347 355 FLOW ANALYSIS, 50 92 170 290 334 347

FLOW CONTROL VALVE, 252 FLOW LINE, 1 17 56 224 FLOW PATH, 270 290 FLOW PROPERTIES, 50 78 92 170 FLOW RATE, 170 281 334 FLOW VISUALISATION, 50 92 102 170 290 334 FLOWERPOT, 354 FLUID ASSISTED, 34 FLUOROCARBON RUBBER, 200 FOAM, 2 15 16 23 34 35 51 75 76 99 101 119 126 135 140 141 145 150 195 204 211 218 224 244 252 253 260 265 282 286 315 324 330 347 379 FOAM-CORE, 36 44 101 149 226 239 259 265 270 283 FOAMING, 53 97 150 288 FOAMING AGENT, 2 44 48 76 99 150 195 244 252 282 FOGGING, 16 FOGGING RESISTANCE, 211 FOOD-CONTACT APPLICATION, 6 266 350 FOOD PACKAGING, 19 41 126 135 182 204 212 238 270 322 324 331 FOOTWEAR, 28 51 76 77 110 141 238 243 266 302 348 363 FOUNTAIN FLOW, 290 310 333 355 FOUR-CAVITY, 17 238 FOUR-COMPONENT, 18 FRACTURE, 151 313 FRACTURE MORPHOLOGY, 8 90 117 187 FUEL CONSUMPTION, 11 80 FUEL RESISTANCE, 200 FUEL SYSTEM, 158 217 FURNITURE, 2 15 24 27 141 244 379 FUSIBLE CORE, 7 158 247 286 352 359 FUSION BONDING, 89 114

G GARDEN FURNITURE, 2 24 27 141 244 259 283 GAS-ASSISTED, 2 7 34 41 44 56 71 75 85 88 97 101 140 146 164 211 247 286 GAS INJECTION, 2 16 41 164 200 247 GAS INJECTION MOULDING, 2 35 41 44 74 75 88 96 97 99 136 140 149 164 175 189 205 211

© Copyright 2002 Rapra Technology Limited

Subject Index

212 230 247 251 268 286 303 324 337 GAS PERMEABILITY, 41 126 135 212 322 GASKET, 6 118 127 147 203 325 GATE, 36 56 162 277 313 316 317 332 333 334 GATING, 5 48 66 100 112 149 159 252 268 269 270 278 280 284 348 GEAR BOX, 256 GEOMETRY, 11 190 286 316 334 GLASS FIBRE-REINFORCED PLASTIC, 15 40 47 48 75 79 117 136 158 162 163 168 173 191 196 199 201 204 211 218 250 252 253 258 265 277 282 290 291 298 302 307 316 317 337 356 362 374 GLASS TRANSITION TEMPERATURE, 158 313 372 GLAZING, 112 GLOSS, 216 247 GLOVE BOX, 293 GOGGLES, 302 GOLF BALL, 307 GOLF CLUB, 256 GRAPHITE FIBREREINFORCED PLASTIC, 310 GRIP, 26 42 51 99 165 203 207 222 229 GROWTH RATE, 63 87 99 146 150 200 203 254 269 293 305 306 336 354

H HANDLE, 14 26 30 42 107 124 141 195 206 211 238 258 266 306 325 331 346 354 HANDLING, 84 104 167 182 245 276 HARDNESS, 39 51 83 115 151 206 211 253 266 306 365 HEALTHCARE APPLICATION, 6 HEAT AGEING, 115 124 266 HEAT DISSIPATION, 2 HEAT FUSION, 89 HEAT RESISTANCE, 41 62 78 108 114 121 136 151 253 256 307 324 356 HEAT TRANSFER, 128 151 290 HEAT TREATMENT, 16 328 HEATED, 1 12 15 16 41 51 55 116 151 194 223 226 236 277 335 HIGH DENSITY POLYETHYLENE, 10 25 33 87 90 199 265 309 310 334

HIGH IMPACT POLYPROPYLENE, 253 HIGH IMPACT POLYSTYRENE, 90 179 363 HIGH SPEED MOULDING, 3 19 75 88 126 135 HINGE, 40 85 279 340 HOLDING PRESSURE, 44 72 75 114 126 135 151 164 231 281 316 317 332 333 355 HOLDING STAGE, 75 88 164 HOLDING TIME, 16 213 313 332 HOLLOW ARTICLE, 2 40 41 136 164 286 352 367 370 374 HORIZONTAL, 10 88 185 209 271 HORIZONTAL MACHINE, 18 29 55 75 140 141 142 194 199 238 247 336 HOT FILLING, 182 HOT PLATE WELDING, 158 HOT RUNNER, 1 4 17 19 24 35 73 75 85 98 100 126 135 140 145 148 149 152 153 163 171 181 186 191 192 194 212 221 223 226 228 231 238 239 242 250 252 257 261 268 270 273 277 278 280 284 294 316 317 325 327 335 346 353 356 362 363 HOT-RUNNER MOULD, 1 17 19 75 126 135 140 148 194 223 238 277 HOT WATER, 116 HOUSEWARES, 24 52 118 119 125 136 204 212 HOUSING, 21 59 85 86 149 181 256 265 302 343 371 377 380 HYDRAULIC, 1 3 15 17 18 27 29 35 75 84 88 99 101 126 130 140 148 171 183 194 199 211 224 230 238 247 287 288 293 297 316 336 349 HYDRAULIC FLUID, 180 HYDROMECHANICAL, 88 97 101 194 247 253 292

I IMMISCIBLE, 282 IMPACT PROPERTIES, 11 78 107 117 218 252 324 328 329 IN-LINE, 35 IN-MOULD ASSEMBLY, 192 240 261 295 IN-MOULD BONDING, 110 IN-MOULD COATING, 116 286 314 IN-MOULD DECORATING, 7 19 34 73 101 109 206 244 251 255

© Copyright 2002 Rapra Technology Limited

260 268 283 303 311 316 317 IN-MOULD LABELLING, 19 240 251 IN-MOULD LAMINATING, 139 240 251 268 IN-MOULD PAINTING, 240 314 INCOMPATIBLE, 279 349 365 372 INDEX-PLATE MOULD, 13 43 181 INDUCTION HEATING, 236 INDUSTRIAL ROBOT, 18 19 51 55 75 80 134 140 141 142 164 199 204 224 244 276 312 363 INJECTION BLOW MOULDING, 30 41 135 INJECTION-COMPRESSION MOULD, 286 INJECTION COMPRESSION MOULDING, 7 51 205 236 240 251 INJECTION MOULD, 1 2 3 10 11 16 17 18 19 27 28 31 41 44 51 52 55 75 80 88 95 98 99 126 129 135 137 139 140 141 142 143 148 150 151 156 164 178 194 199 204 211 218 223 224 238 244 251 271 277 282 286 290 294 310 313 316 317 328 332 333 334 341 347 355 363 367 INJECTION PORT, 149 INJECTION PRESS, 1 2 3 11 17 18 19 27 28 29 41 51 52 55 75 80 88 126 141 142 164 244 INJECTION PRESSURE, 2 16 17 28 29 51 88 115 128 194 205 218 222 224 226 229 238 244 283 291 297 313 316 317 332 355 INJECTION SPEED, 16 18 45 75 88 89 117 126 128 135 150 152 170 187 194 205 218 238 269 281 290 291 313 346 347 332 INJECTION STRETCH BLOW MOULDING, 186 INJECTION TEMPERATURE, 223 INJECTION TIME, 114 151 218 316 333 355 INJECTION UNIT, 3 16 18 19 27 29 36 51 55 60 67 75 80 88 97 101 109 122 126 130 135 140 142 149 153 154 155 159 167 179 192 194 199 204 211 212 222 223 224 226 227 229 238 241 244 247 249 252 259 260 265 271 292 305 306 307 316

109

Subject Index

326 331 INJECTION VOLUME, 55 148 164 194 226 244 INNER TUBE, 200 INSERT, 16 17 18 46 51 55 142 164 238 244 247 253 266 305 306 316 317 334 INSERT MOULD, 5 11 15 17 20 35 36 37 39 40 41 47 48 54 58 60 62 75 82 83 85 87 89 94 98 99 107 108 114 115 121 122 127 130 132 134 137 138 139 140 142 143 151 154 155 160 164 165 185 190 194 196 197 199 200 203 205 207 209 212 213 217 222 227 229 234 239 250 251 254 269 276 279 316 317 363 372 375 377 INSERT MOULDING, 2 11 16 17 18 30 35 41 42 43 46 51 55 69 74 75 80 82 88 89 90 101 122 127 140 141 142 164 194 196 207 211 218 223 244 247 251 253 256 266 276 277 291 293 325 327 337 348 INSTRUMENT DIAL, 331 INSTRUMENT PANEL, 82 316 324 INTEGRAL HANDLE, 238 INTEGRAL MOULDING, 51 INTEGRAL SKIN FOAM, 44 INTERFACE, 39 92 93 128 264 282 290 310 333 355 INTERFACIAL ADHESION, 25 78 128 151 177 INTERFACIAL PROPERTIES, 90 92 128 INTERNAL HEATING, 223 284 INTERNAL STRESS, 17 44 141 INVESTMENT, 79 81 98 174 180 232 254 275 295 305 306 318 344 351 366

J JAR, 186 JOINING, 294 302 JOINT, 46 80 197 302 372 JUNCTION BOX, 191

K KEY, 191 302 325 KEYBOARD, 238 KEYPAD, 82 293 301 307 326 361 372 KITCHENWARE, 14 KNOB, 26 285 296 301 306 326

110

331

L LABEL, 19 LADDER, 372 LAMELLAR, 286 324 328 360 LAMINAR FLOW, 282 LAMINATE, 16 18 33 41 75 115 117 126 135 177 196 204 225 244 247 263 286 310 315 328 330 358 LAMINATED FILM, 11 LAMINATING, 139 240 251 268 LAMINATION, 7 LARGE-COMPONENT, 2 11 41 75 88 140 141 142 224 238 286 316 317 334 LARGE-MACHINE, 52 75 88 142 244 LATERAL INJECTION, 140 148 223 LAWN MOWER, 48 LEAD TIME, 108 206 222 LEGISLATION, 314 350 LEISURE APPLICATION, 141 379 LENS, 84 127 321 326 331 339 372 LICENCE, 10 23 86 99 143 192 360 LID, 19 LIGHT DEGRADATION, 253 266 LIGHT SWITCH, 213 LIGHT TRANSMISSION, 266 313 LIGHTWEIGHT, 51 80 298 337 LIQUID COMPOSITE MOULDING, 286 LIQUID CRYSTAL POLYMER, 38 116 173 214 310 377 LIQUID INJECTION MOULDING, 16 67 115 132 146 157 363 LIQUID RUBBER, 5 6 9 16 35 39 62 66 67 74 82 96 97 108 114 115 121 125 129 132 136 139 146 147 151 157 159 163 189 200 212 241 307 363 LOAD BEARING, 5 254 286 LOST-CORE PROCESS, 32 40 116 158 205 232 236 251 254 256 292 298 304 312 338 356 357 359 367 369 371 374 377 LOW DENSITY POLYETHYLENE, 78 88 155 156 199 LOW PRESSURE, 7 34 240 244 273 283 286 298 316 317

LOW-PRESSURE MOULDING, 2 44 51 141 247 LOW TEMPERATURE MOULDING, 205 LOW TEMPERATURE PROPERTIES, 121 253

M MACHINING, 127 129 191 194 306 326 359 MAGNETIC FILLER, 138 MAINTENANCE, 1 15 142 244 MALEIC ANHYDRIDE COPOLYMER, 246 MANIFOLD, 15 69 100 158 181 221 232 239 252 254 256 257 284 292 298 308 312 327 354 356 357 359 370 371 374 377 MANIPULATOR, 19 55 75 140 142 204 244 MANUFACTURE, 77 166 193 MANUFACTURER, 12 85 86 105 133 148 230 MANUFACTURING, 84 160 168 176 228 289 MARBLISING, 74 135 251 MATERIALS SELECTION, 30 59 64 83 94 200 224 265 MECHANICAL PART, 2 17 18 19 65 75 80 266 279 MECHANICAL PROPERTIES, 4 5 8 9 11 14 16 17 28 33 39 41 42 44 46 47 49 51 56 63 76 78 83 85 107 114 115 117 120 121 124 132 136 138 139 141 149 151 153 159 169 173 196 199 204 206 207 211 214 217 218 222 223 229 237 243 252 253 262 266 271 281 286 287 290 298 306 307 308 310 313 316 317 322 324 328 329 330 334 341 342 348 365 370 374 377 MEDICAL APPLICATION, 2 6 16 21 28 37 75 105 108 114 121 125 129 137 163 200 204 212 223 235 261 284 MELT, 8 15 56 128 290 349 MELT FILTER, 336 MELT FLOW, 1 17 126 135 152 170 181 282 290 310 316 317 332 333 334 346 347 355 MELT FLOW INDEX, 78 92 MELT PROPERTIES, 50 170 205 MELT TEMPERATURE, 4 16 45 50 89 126 128 135 153 170 223 263 281 290 316 320 332 333 334 346 355 372

© Copyright 2002 Rapra Technology Limited

Subject Index

MELT VISCOSITY, 50 78 170 218 282 316 332 334 METAL ADHESION, 108 115 307 METAL INSERT, 16 17 238 363 METAL REPLACEMENT, 11 43 48 158 247 256 307 366 374 METERING, 61 67 132 288 308 MICROCELLULAR, 2 7 35 53 99 101 150 286 MICROMOULDING, 7 40 61 97 101 212 MICROSTRUCTURE, 93 290 310 MISCIBILITY, 25 MIXING, 5 41 67 88 132 193 242 258 267 288 MOBILE PHONE, 52 86 98 99 108 118 181 184 MODEL, 8 93 128 193 248 290 328 333 334 MODULAR, 3 11 16 18 29 36 67 74 75 88 101 109 125 140 141 142 164 194 199 247 249 293 318 336 MONOSANDWICH, 154 MORPHOLOGICAL PROPERTIES, 8 90 117 187 290 310 313 328 355 MOTOR, 27 97 256 302 MOULD, 1 2 3 10 11 12 15 16 17 18 19 21 22 27 28 41 43 51 52 55 75 77 80 81 84 86 87 88 99 104 109 113 119 126 129 135 140 141 142 148 150 151 152 155 160 164 165 167 181 182 192 194 198 199 204 209 211 218 223 224 228 229 238 244 245 247 250 253 271 277 282 283 287 290 308 313 316 317 332 333 334 337 346 347 355 363 365 380 MOULD CARRIER, 18 142 164 244 288 MOULD CAVITY, 18 21 73 100 102 111 120 129 190 224 227 248 282 290 333 355 MOULD CHANGING, 35 51 101 130 140 141 199 204 376 MOULD CLAMPING, 234 MOULD CLOSING, 1 18 51 88 199 224 238 316 317 MOULD COOLING, 1 17 75 141 191 205 211 244 263 313 316 332 363 MOULD CORE, 3 10 115 116 190 199 211 212 316 317 MOULD CYCLE, 1 2 17 19 52 75 88 140 141 142 194 211 238 247 253 276 332

MOULD DESIGN, 5 11 20 21 37 39 40 54 61 72 98 106 129 143 145 149 151 190 194 227 231 261 321 327 345 368 375 MOULD FILLING, 1 2 17 18 44 75 110 114 126 135 149 150 151 159 164 172 181 193 218 221 239 259 264 270 277 280 290 313 316 317 319 332 333 334 340 347 355 MOULD FLOW, 1 17 58 102 263 290 310 316 317 332 333 334 347 355 MOULD GEOMETRY, 313 MOULD HEATING, 194 223 MOULD INSERT, 66 87 142 164 199 334 MOULD MAKING, 6 10 73 79 83 106 127 129 137 146 153 185 191 194 222 261 285 296 306 345 MOULD OPENING, 17 18 27 51 55 75 88 137 199 238 244 271 277 MOULD PACKING, 332 333 334 355 MOULD RELEASE, 108 121 132 MOULD SHRINKAGE, 72 332 MOULD SLIDE CORE, 115 190 MOULD TEMPERATURE, 5 16 66 89 114 115 117 121 128 132 151 159 170 187 205 223 224 239 259 260 281 290 313 316 320 332 333 334 355 MOULDED INTERCONNECT DEVICE, 95 139 167 212 MOULDED-IN, 270 MOULDING FAULT, 28 141 218 224 MOULDING PRESSURE, 2 16 17 28 29 51 88 194 218 224 238 244 313 316 317 332 355 MOVABLE CORE, 179 194 199 211 239 MULTI-BARREL, 351 MULTI-CAVITY, 17 98 182 238 MULTI-CAVITY MOULD, 10 17 19 21 75 87 88 104 109 126 129 135 140 141 142 150 155 181 192 194 238 250 271 277 284 301 306 308 327 333 340 353 MULTI-CHANNEL, 28 199 MULTI-COLOUR MOULD, 17 18 27 60 73 75 80 109 140 141 142 153 204 247 255 271 296 302 308 321 325 326 327 331 335 336 339 344 349 353 363

© Copyright 2002 Rapra Technology Limited

372 MULTI-COMPONENT, 2 3 5 9 10 13 14 17 18 19 22 27 28 29 31 32 33 34 41 44 52 53 55 60 61 64 65 68 69 72 74 75 80 89 90 94 96 97 99 104 113 114 119 124 125 126 129 137 138 139 140 142 145 149 151 156 164 167 172 179 181 184 185 189 191 197 199 200 203 204 208 209 210 212 218 224 229 241 248 251 260 261 263 271 281 284 288 297 299 302 305 306 311 320 325 339 342 349 353 358 361 365 368 372 373 376 378 379 MULTI-GATE, 239 257 273 294 MULTI-INJECTION, 75 140 142 223 MULTI-LAYER, 8 11 18 33 41 69 74 105 109 111 126 135 136 140 142 152 182 186 190 193 200 212 216 231 263 264 267 274 282 322 323 328 360 362 MULTI-MATERIAL MOULDING, 2 3 17 18 19 25 26 27 28 29 30 35 41 43 52 55 60 69 73 75 80 88 93 95 101 106 109 118 131 140 141 142 146 147 151 153 157 164 165 194 199 204 208 211 218 224 233 235 239 240 247 251 253 261 271 286 293 296 307 319 320 321 325 327 331 335 344 345 354 375 MULTI-SHOT MOULDING, 30 57 63 73 107 118 167 175 176 179 192 201 202 206 222 239 241 301 MULTI-STATION, 51 141 176 226 244 259 283 MULTIPLE INJECTION MOULDING, 2 3 18 19 27 28 29 41 75 93 148 166 223 224 249 301

N NANOMOULDING, 37 NAPPY, 318 NATURAL FIBRE-REINFORCED PLASTIC, 35 NATURAL RUBBER, 114 167 200 NEEDLE VALVE, 17 280 NEWTONIAN, 334 NITRILE RUBBER, 81 146 151 199 200 NOISE REDUCTION, 18 88 244 293 297 312

111

Subject Index

NOZZLE, 1 2 3 15 17 19 24 27 28 35 41 51 69 75 76 84 100 133 136 140 141 142 147 148 149 162 171 194 199 204 221 223 224 239 242 244 247 252 258 265 271 277 287 294 305 308 316 317 347 354 NYLON, 2 5 16 17 18 30 38 39 42 81 89 99 107 108 117 126 131 132 135 147 151 158 162 167 169 179 186 189 191 194 199 203 204 211 212 218 238 246 253 256 277 285 354 356 369 NYLON-12, 85 139 151 199 302 325 NYLON-6, 47 64 85 90 114 117 121 136 162 163 168 177 196 199 204 211 217 253 260 281 298 307 325 362 NYLON-6,12, 114 151 194 NYLON-6,6, 47 64 90 114 121 158 199 204 211 277 307 325

O OFFICE EQUIPMENT, 2 119 132 336 OFFICE FURNITURE, 141 OIL RESISTANCE, 62 90 108 329 374 OPTICAL DISC, 35 74 99 290 OPTICAL PROPERTIES, 1 16 18 19 28 51 80 103 112 126 135 164 194 238 247 253 266 271 290 313 333 342 ORGANOSILOXANE POLYMER, 61 74 ORIENTATION, 4 290 313 316 317 331 OUTPUT, 35 76 79 86 87 95 99 104 155 156 167 254 259 283 306 326 337 371 372 OUTSERT MOULDING, 251 OVERMOULDING, 5 11 15 17 20 35 36 37 39 40 41 47 48 54 58 60 62 75 82 83 85 87 89 94 98 99 107 108 114 115 121 122 127 130 132 134 137 138 139 140 142 143 151 154 155 160 164 165 185 190 196 197 199 200 203 205 207 209 212 213 217 222 227 229 234 239 250 251 254 269 276 279 284 285 289 293 302 306 325 326 329 340 348 352 354 370 377 OXYGEN PERMEABILITY, 135 144 152 270 OZONE RESISTANCE, 42 115

112

P PACKAGING, 2 3 19 28 29 30 41 52 75 109 111 126 135 141 144 145 149 152 163 182 204 211 223 238 239 261 318 324 350 354 PACKAGING CONTAINER, 111 137 144 155 182 322 336 340 PACKAGING TUBE, 126 135 PACKING PRESSURE, 333 355 PALLET, 283 PART REMOVAL, 43 75 98 137 140 141 142 164 200 222 229 305 PART WEIGHT, 1 87 141 212 242 259 260 265 283 PARTING LINE, 140 155 156 332 PATENT, 15 23 59 78 81 98 112 126 137 155 156 157 158 160 212 239 252 269 307 311 369 370 PATENT INFRINGEMENT, 186 PEDAL, 305 PEEL STRENGTH, 47 68 151 300 PEEL TEST, 5 47 114 151 PERMEABILITY, 41 126 135 144 149 152 193 PERSONAL CARE PRODUCT, 135 331 PHARMACEUTICAL APPLICATION, 126 135 204 PHOTOGRAPHIC APPLICATION, 59 204 PIGMENT, 80 217 258 290 306 PIPE, 288 PISTON, 17 55 100 244 288 PLAQUE, 282 290 PLASTICATING, 283 291 PLASTICISATION, 2 3 17 19 23 29 41 67 75 77 88 133 140 164 231 238 244 267 363 PLATE, 117 260 PLATEN, 10 27 55 67 77 84 97 115 125 137 153 160 161 164 165 171 190 226 283 292 293 305 321 327 331 346 354 PLUG, 260 PLUNGER, 283 PNEUMATIC, 17 35 126 148 194 244 POLYACETAL, 17 81 114 167 200 217 318 329 372 POLYALKENE, 8 19 24 36 48 89 90 187 195 239 253 266 POLYAMIDE, 2 5 16 17 18 30 38 39 42 81 89 99 107 108 117 126 131 132 135 147 151 158 162

167 169 179 186 189 191 194 199 203 204 211 212 218 238 246 253 256 277 285 299 302 326 337 354 356 363 365 369 POLYAMIDE-12, 85 139 151 199 302 325 POLYAMIDE-4,6, 356 POLYAMIDE-6, 47 85 90 114 117 121 136 163 177 196 199 204 211 217 253 260 298 307 325 362 POLYAMIDE-6,12, 114 151 194 POLYAMIDE-6,6, 47 114 121 307 325 356 374 POLYARYLENE SULFONE, 90 POLYBUTYLENE TEREPHTHALATE, 5 16 38 47 108 114 117 121 151 174 194 196 199 201 204 211 212 240 253 258 285 290 300 354 360 368 373 POLYCAPROLACTAM, 47 177 POLYCARBONATE, 2 4 17 25 38 40 42 50 56 86 89 90 92 98 103 112 165 170 174 179 191 199 203 204 211 212 223 253 260 265 266 284 285 290 300 306 310 318 328 332 360 363 379 POLYCHLOROPRENE, 306 POLYEPOXIDE, 282 POLYESTER ELASTOMER, 282 POLYESTER-URETHANE, 299 POLYETHER SULFONE, 38 90 138 220 POLYETHER URETHANE, 299 POLYETHERIMIDE, 38 310 POLYETHYLENE, 2 10 17 25 30 33 42 78 87 88 90 106 126 135 137 141 149 152 155 156 191 199 204 211 212 265 309 310 334 340 379 POLYETHYLENE NAPHTHALATE, 126 135 144 163 182 POLYETHYLENE TEREPHTHALATE, 10 35 41 74 87 91 101 111 126 135 144 145 152 163 173 182 186 191 199 212 214 231 270 274 309 350 354 POLYMERIC COMPATIBILISER, 177 POLYMETHYL METHACRYLATE, 11 40 89 90 179 238 355 POLYMETHYLENE OXIDE, 40 POLYOXYMETHYLENE, 40 299 POLYPHENYLENE OXIDE, 107

© Copyright 2002 Rapra Technology Limited

Subject Index

114 121 201 204 211 253 POLYPHENYLENE SULFIDE, 38 47 356 377 POLYPROPYLENE, 1 2 4 8 11 17 19 20 25 30 38 42 48 58 72 78 79 80 83 85 87 88 93 99 104 123 124 126 131 135 141 149 152 155 156 167 177 179 187 194 198 199 201 202 204 206 207 211 218 226 238 239 241 244 246 250 252 253 259 266 285 293 306 309 310 318 319 322 325 326 331 337 341 344 345 346 354 362 364 368 373 POLYSILOXANE, 16 61 74 115 POLYSTYRENE, 2 17 25 33 36 40 59 88 89 90 93 128 149 179 187 199 204 211 222 229 260 299 306 313 333 340 347 363 POLYSULFONE, 377 POLYURETHANE, 16 18 51 64 90 179 199 238 260 281 285 288 299 307 337 363 POLYURETHANE ELASTOMER, 16 18 51 191 199 POLYVINYL ALCOHOL, 116 POLYVINYL CHLORIDE, 30 51 149 191 199 POLYVINYL ESTER, 307 POLYVINYLBENZENE, 89 90 93 POLYVINYLIDENE CHLORIDE, 199 POLYVINYLIDENE FLUORIDE, 11 POST-MOULD, 121 POWDER INJECTION MOULDING, 74 101 POWDER MOULDING, 273 POWER STEERING, 304 POWER TOOL, 325 PRECISION, 12 19 41 80 130 276 PRECISION MOULDING, 3 19 80 101 129 PREDICTIVE SOFTWARE, 43 PREFORM, 35 36 41 74 91 98 101 111 126 134 135 139 144 145 152 155 156 161 163 179 182 186 193 212 227 228 231 239 274 286 349 350 354 361 PREHEATING, 16 51 55 PREPREG, 286 349 350 354 361 PRESS, 24 56 160 168 171 216 356 PRESSURE, 4 7 15 17 34 41 84 240 244 273 274 282 290 317 334 374 PRESSURE CONTROL, 2 28 75 194 199 224 238 265 346

PRESSURE DISTRIBUTION, 49 334 PRESSURE PROFILE, 164 332 355 PRICE, 15 36 62 146 203 204 254 308 335 356 371 377 PRIMERLESS, 115 PRINTED CIRCUIT, 116 PRINTING, 82 141 269 317 PROBLEM PREVENTION, 142 250 278 367 PROCESS CONTROL, 2 12 23 24 40 43 74 75 84 130 135 145 152 171 205 242 244 252 274 283 316 332 PROCESSABILITY, 115 121 237 329 PROCESSING, 4 7 8 12 13 14 15 16 30 39 42 53 56 76 77 85 86 89 105 117 125 154 161 166 168 176 187 193 198 209 210 219 228 248 264 266 274 286 289 299 342 343 348 349 356 358 365 PRODUCT, 166 198 219 228 PRODUCT ANNOUNCEMENT, 15 21 24 26 42 59 60 61 67 69 74 76 77 84 86 101 109 123 139 143 145 146 147 153 156 157 158 160 161 171 182 185 202 205 208 215 216 228 233 237 261 267 285 288 314 336 345 360 361 362 364 368 369 370 PRODUCT DESIGN, 30 159 PRODUCT DEVELOPMENT, 48 62 79 107 108 155 206 217 222 229 296 PRODUCTION, 12 24 86 168 176 PRODUCTION CELL, 43 57 74 80 101 104 106 140 141 192 254 269 294 305 PRODUCTION COST, 28 41 42 43 51 52 80 88 142 158 176 197 206 209 231 237 256 285 296 304 342 PRODUCTION RATE, 19 51 98 108 127 137 141 155 165 176 238 245 259 269 375 PRODUCTIVITY, 4 17 19 28 30 41 43 86 95 104 122 141 161 238 247 249 276 PROFILE, 16 17 128 266 PROFITABILITY, 324 PROGRAMMABLE LOGIC CONTROLLER, 51 122 PROPERTIES, 1 2 4 6 8 9 11 12 14 16 17 18 19 28 30 33 39 41 42

© Copyright 2002 Rapra Technology Limited

45 46 50 51 65 67 78 80 85 89 90 92 103 105 112 114 115 117 120 121 124 125 126 128 132 135 136 138 141 144 149 151 162 164 168 170 173 182 186 187 193 194 198 205 207 211 214 218 238 245 247 253 266 271 282 343 345 364 375 PROPORTIONAL VALVE, 75 244 PROTOTYPE, 63 83 85 127 292 293 PUMP, 15 36 101 256 288 371 PUSH-PULL INJECTION MOULDING, 164 251

Q QUALITY, 4 12 76 77 80 105 QUALITY CONTROL, 12 19 41 43 80 130 148 189 204 230 245 268 276 306 309 QUICK COLOUR CHANGING, 1 55 QUICK MATERIALS CHANGING, 55 QUICK MOULD CHANGING, 35 51 101 204 QUICK PRODUCT CHANGING, 19 141

R RADIATION CROSSLINKING, 302 RADIATOR, 11 RAZOR, 88 RECLAIM, 18 28 41 75 126 135 140 141 145 164 199 204 211 218 221 231 238 244 247 249 253 294 378 RECYCLABILITY, 63 78 253 266 274 364 RECYCLED CONTENT, 78 105 145 149 164 212 226 227 231 239 240 241 242 252 259 260 265 270 324 RECYCLING, 15 63 70 71 78 85 111 130 141 177 212 231 253 256 266 274 298 329 336 337 342 343 346 350 354 364 375 377 378 REFRIGERATOR, 252 REFUSE CONTAINER, 238 REGRIND, 23 324 327 364 REGULATION, 129 314 380 REINFORCED PLASTIC, 4 12 15 40 45 46 47 48 66 74 75 79 97 117 136 158 164 168 173 191

113

Subject Index

193 196 199 201 204 205 211 214 218 250 252 253 265 277 282 286 290 291 298 306 307 310 315 316 317 325 337 359 362 369 374 377 RELEASE AGENT, 308 RESIDUAL STRESS, 49 334 RESILIENCE, 266 RESIN TRANSFER MOULDING, 193 256 286 RETROFIT, 15 29 36 99 109 160 179 239 254 362 REVIEW, 6 7 44 61 95 101 109 139 146 153 157 182 205 251 261 273 302 358 RHEOLOGICAL PROPERTIES, 1 2 14 16 17 50 78 92 115 126 135 149 151 159 170 193 205 211 218 239 243 266 270 282 290 310 316 317 332 333 334 347 355 364 RIBBED, 1 19 56 333 334 RIGID, 39 47 49 114 138 139 151 168 195 199 204 218 223 237 281 337 365 ROBOT, 18 19 31 35 51 55 73 75 79 80 98 101 104 106 134 137 140 141 142 146 150 164 179 199 204 222 224 229 244 245 254 260 274 276 292 293 305 306 354 371 372 ROLLER, 6 250 ROTARY MACHINE, 140 141 156 185 226 233 244 259 292 ROTATING TABLE, 10 13 27 73 75 140 142 164 166 180 191 199 222 224 227 238 239 240 247 306 325 363 ROTATION, 21 115 165 209 227 ROTATIONAL MOULD, 5 16 17 18 43 52 76 98 99 114 130 137 140 141 151 155 160 175 179 194 199 211 253 271 277 349 361 372 375 ROUGHNESS, 39 116 151 RUBBER, 2 5 6 9 11 12 14 16 17 18 20 22 26 32 34 35 39 42 43 47 51 53 55 58 59 62 63 66 67 68 70 71 74 75 79 80 81 82 83 85 87 89 90 94 95 97 100 104 107 108 109 110 113 114 115 121 124 125 127 129 131 132 136 138 139 140 141 142 146 147 151 153 157 159 163 165 166 167 168 169 172 178 179 189 190 191 193 194 195 198 199 200 203 204 206 207 211 212 218 222 223 229 238 239 241 242 245

114

250 253 258 260 266 271 277 282 284 285 286 288 290 291 293 295 299 300 302 306 307 320 325 326 331 337 344 345 346 348 349 353 363 RUBBER TO METAL BONDING, 42 43 81 RUBBER-MODIFIED, 11 218 290 RUNNER, 54 58 RUNNERLESS MOULDING, 1 17 19 75 126 135 140 148 194 223 238 277

S SANDWICH, 15 105 154 220 274 SANDWICH MOULDING, 18 19 23 28 35 41 74 75 109 112 117 134 140 142 149 171 204 211 212 217 219 226 227 238 247 249 251 253 258 259 260 286 308 315 354 375 380 SANDWICH STRUCTURE, 99 100 102 117 137 177 204 238 244 253 257 267 283 295 299 311 319 323 362 364 SANITARY TOWEL, 318 SANITARYWARE, 141 SATURATED POLYESTER, 116 117 194 282 SAUCEPAN, 14 SCANNING ELECTRON MICROSCOPY, 40 310 328 SCRAP POLYMER, 78 141 174 221 272 283 309 345354 362 375 378 SCRAPER, 207 SCRATCH RESISTANCE, 11 103 112 324 SCREEN, 1 183 336 380 SCREW, 1 2 3 15 18 24 27 29 41 56 88 217 219 258 283 287 306 SCREW CAP, 87 155 SCREW DESIGN, 41 67 97 244 267 336 SCREW DIAMETER, 18 29 75 212 226 244 260 291 SCREW DRIVE, 260 SCREW INJECTION MOULDING MACHINE, 41 55 238 244 247 SCREW LENGTH, 291 SCREW PLASTICISATION, 2 3 19 29 41 75 164 238 244 SCREW SPEED, 194 SCREW THREAD, 18 46 SCREWDRIVER, 58 107 141 SEAL, 2 17 18 19 20 61 75 80 85

87 108 159 160 206 212 266 302 305 307 SEALANT, 6 115 SEAT, 141 226 259 SELF-ADHESION, 16 47 62 115 121 132 147 SENSOR, 2 40 140 237 282 SEQUENTIAL INJECTION MOULDING, 1 2 4 11 17 27 75 90 126 128 135 140 145 164 186 212 245 247 251 258 265 271 277 280 316 317 SEQUENTIAL MOULDING, 73 182 205 234 333 334 347 SEQUENTIAL VALVE GATING, 56 242 SERVICE LIFE, 130 245 SERVOCONTROL, 18 75 140 142 SERVO MOTOR, 3 101 157 254 276 293 306 SERVO VALVE, 75 140 244 SHAPE, 24 286 334 SHAPE FACTOR, 116 367 SHEAR, 4 8 56 88 132 196 264 290 310 316 SHEAR STRESS, 4 290 308 316 SHEAR VISCOSITY, 218 SHEET, 286 316 SHELF LIFE, 5 87 126 132 152 182 SHOCK ABSORPTION, 222 229 266 SHOE, 51 266 302 SHOT SIZE, 10 29 101 217 259 277 283 291 305 306 SHOT WEIGHT, 36 98 106 222 226 229 326 340 SHOWER, 108 147 307 SHREDDER FLUFF, 78 SHRINK FIT, 245 SHRINKAGE, 44 49 51 72 76 78 211 239 265 290 332 341 346 SILICATE, 1 4 16 SILICONE, 12 282 SILICONE ELASTOMER, 5 6 9 16 35 39 47 55 62 66 67 74 82 96 97 108 114 115 121 125 129 132 136 138 139 146 147 151 157 159 163 167 169 189 200 204 212 241 245 260 300 307 363 SIMULATION, 1 4 8 17 20 93 129 151 172 189 248 264 282 290 333 334 347 355 SIMULTANEOUS, 4 182 193 334 SINK MARK, 44 56 332 SIZE, 15 56 77 84 133 160 161 286 291 SIZE REDUCTION, 78 SKI BOOT, 28 266 345 SKIN, 11 15 17 18 28 85 99 126

© Copyright 2002 Rapra Technology Limited

Subject Index

135 140 141 164 211 218 224 253 290 308 310 313 333 337 347 355 SKIN-CORE, 8 117 152 159 170 177 187 239 242 258 259 264 265 290 294 310 355 SKIN FORMATION, 270 364 SLIDE CORE, 239 305 SLIDING, 13 87 100 240 325 SLIP, 290 358 SMALL COMPONENT, 37 224 277 332 SMART CARD, 74 137 269 SNAP-FIT, 65 192 340 SOFT DRINK BOTTLE, 350 SOFT-TOUCH, 2 15 26 28 30 41 42 54 75 80 89 109 127 153 163 165 179 203 206 207 SOFTNESS, 51 217 266 302 337 SOFTWARE, 4 18 49 83 157 229 245 252 307 316 317 325 335 347 SOLE, 51 110 348 SOLIDIFICATION, 316 SOLUBLE CORE, 256 SPECIAL EFFECTS, 140 SPEED, 4 15 24 130 160 162 SPORTS EQUIPMENT, 28 77 204 256 266 312 358 SPORTS SHOE, 51 266 302 348 SPOUT, 137 155 340 SPRUE, 149 SPRUELESS, 61 STABILISER, 24 258 STABILITY, 78 253 STACK MOULD, 10 31 95 98 99 137 139 143 150 156 185 212 227 STANDARD, 24 36 77 230 350 STARVE FEEDING, 217 STEERING GEAR, 48 304 STEERING WHEEL, 48 62 STIFFNESS, 112 120 149 151 196 324 329 334 STRENGTH, 115 196 262 298 322 329 370 STRESS, 17 41 49 141 218 243 307 313 316 317 334 STRUCTURAL FOAM, 23 34 119 STRUCTURAL FOAM MOULDING, 44 76 251 268 STYRENE-ACRYLONITRILE COPOLYMER, 194 199 259 266 360 362 379 STYRENE-BUTADIENESTYRENE BLOCK COPOLYMER, 42 199 293 STYRENE-ETHYLENE

BUTYLENE-STYRENE BLOCK COPOLYMER, 42 194 199 211 237 253 266 325 STYRENE-ISOPRENESTYRENE BLOCK COPOLYMER, 199 SUPERCRITICAL GAS, 2 150 SURFACE, 15 39 105 161 168 228 SURFACE DEFECT, 44 SURFACE ENERGY, 115 SURFACE FINISH, 2 5 11 28 41 42 136 141 218 239 247 252 259 265 283 324 SURFACE PROPERTIES, 45 114 151 SURFACE TREATMENT, 11 19 38 43 132 140 141 194 244 303 307 311 314 316 317 346 SURFACTANT, 258 308 SWITCH, 62 82 306 325 SYNDIOTACTIC, 40 313 SYNTHETIC CORK, 141 SYNTHETIC MARBLE, 225

T TALC, 1 4 218 244 328 TAMPER-EVIDENT, 87 340 TAMPER RESISTANT, 318 TAMPO PRINTING, 141 TEAR STRENGTH, 115 266 TELECOMMUNICATIONS APPLICATION, 118 202 TELEPHONE, 2 28 52 218 301 307 326 TELEVISION, 2 149 376 TEMPERATURE, 1 12 16 17 24 39 41 51 85 117 149 162 223 266 277 282 313 348 TEMPERATURE CONTROL, 1 17 51 55 66 199 201 224 332 335 TEMPERATURE CONTROL EQUIPMENT, 186 269 TEMPERATURE DISTRIBUTION, 114 151 TEMPERATURE RANGE, 115 284 329 374 TENNIS RACQUET, 312 TENSILE PROPERTIES, 5 9 14 28 33 42 46 78 115 169 218 266 313 328 TENSION, 113 313 TEST, 9 33 47 68 72 151 272 313 328 341 350 TEST SPECIMEN, 39 128 TESTING, 4 5 35 39 47 90 115 196 245 TEXTILE, 34 51 89 234 247 316

© Copyright 2002 Rapra Technology Limited

317 TEXTILE OVERMOULDING, 234 THERMAL CONDUCTIVITY, 20 158 284 334 374 THERMAL DEGRADATION, 115 124 266 308 THERMAL EXPANSION, 28 78 328 THERMAL PROPERTIES, 12 16 28 85126 135 223 247 290 313 316 328 332 333 334 355 THERMAL STABILITY, 41 62 78 108 114 121 136 151 253 256 307 324 356 THERMOFORMING, 11 19 196 286 THERMOMECHANICAL PROPERTIES, 5 9 39 114 266 313 328 THERMOPLASTIC ELASTOMER, 5 12 16 17 18 20 24 26 30 35 42 45 51 53 54 58 63 70 71 75 79 80 83 87 89 90 104 107 114 123 124 127 131 138 139 140 146 153 163 165 167 172 178 179 184 191 194 198 199 202 203 204 206 207 211 212 237 238 239 241 250 253 258 260 266 277 282 285 293 295 299 301 302 306 307 320 325 326 331 344 345 346 348 349 354 363 THERMOSET, 6 13 14 25 35 37 38 39 40 41 55 61 65 67 69 74 80 82 85 91 95 97 101 102 109 111 113 119 120 123 125 129 130 134 138 139 140 142 143 146 147 157 166 180 188 202 205 215 235 236 251 255 256 267 272 276 279 282 286 288 291 309 310 330 338 351 352 353 358 359 371 THICK-WALL, 2 88 113 140 THICKNESS, 4 11 16 51 56 112 117 128 151 218 225 226 244 247 264 277 282 290 313 328 333 334 347 355 364 THIN-WALL, 2 11 19 51 75 88 101 126 135 140 151 152 205 240 269 354 THREAD, 46 190 THREE-COLOUR INJECTION MOULDING, 18 19 247 271 THREE-COMPONENT, 18 199 204 THREE-DIMENSIONAL, 20 129 139 286 296 299 325 334 THREE-LAYER, 126 245

115

Subject Index

THREE-PART, 18 199 204 THREE-SHOT MOULDING, 285 301 TIE LAYER, 322 TIEBAR, 97 133 171 212 222 226 229 291 292 361 TIEBARLESS, 35 43 97 101 106 241 254 293 306 326 372 TOGGLE, 3 24 27 75 77 88 164 332 TOGGLE PRESS, 3 27 75 88 101 140 146 157 164 238 TOILET, 149 194 226 259 TOLERANCE, 19 101 141 TOOLING, 4 20 24 35 56 81 105 108 121 162 166 178 186 208 225 285 289 306 307 325 326 353 354 TOOLS, 58 107 124 141 167 203 211 331 354 TOOTHBRUSH, 30 104 165 167 194 204 206 239 346 TOOTHPASTE TUBE, 10 135 191 212 TORPEDO, 148 TOUCH, 2 28 41 75 80 266 TOYS, 75 137 192 197 211 239 253 261 266 284 375 TRANSFER INJECTION MOULDING, 41 TRANSFER MECHANISM, 95 TRANSFER MOULDING, 6 13 43 130 361 TRANSITION PHENOMENA, 50 170 205 TRANSLUCENCY, 306 266 313 322 TRANSPARENT, 19 229 325 333 TRANSPORT APPLICATION, 63 TRAY, 150 354 TROUBLESHOOTING, 250 278 TUB, 354 TUBE, 126 135 152 TURNTABLE, 10 166 180 222 227 326 340 TWIN-INJECTION, 281 TWIN-PLATEN, 35 36 88 99 101 106 233 TWIN-SCREW, 244 247 TWIN-STATION, 271 TWO-CAVITY, 140 141 164 TWO-COLOUR, 98 137 150 204 211 284 293 305 TWO-COLOUR INJECTION MOULDING, 3 17 18 19 26 27 28 51 52 75 130 140 141 142 164 199 211 226 227 238 253 271 294 323 TWO-COMPONENT, 18 19 23 39 46 51 59 67 79 83 87 98 115 123

116

129 130 132 141 147 150 155 156 169 183 188 215 224 227 239 258 267 271 346 380 TWO-COMPONENT MOULD, 61 113 271 TWO-COMPOUND MOULD, 21 243 TWO-LAYER, 217 282 298 TWO-MATERIAL INJECTION MOULDING, 2 3 17 18 27 28 29 41 46 51 52 60 61 62 75 88 140 141 142 151 164 169 194 199 204 211 218 223 224 226 227 238 244 247 253 266 271 277 296 302 306 326 337 340 TWO-PART, 18 19 23 39 46 51 59 67 79 83 87 98 115 123 129 130 132 141 147 150 155 156 169 183 188 215 224 227 239 258 267 271 TWO-PLATEN, 35 36 88 99 101 106 233 TWO-SHOT, 26 54 89 90 115 121 127 156 207 229 TWO-STAGE, 128 TWO-STAGE INJECTION MOULDING, 307

U UNDER-THE-BONNET APPLICATION, 80 132 158 304 374 377 UNFILLED, 199 282 UNSATURATED POLYESTER, 291 307 UV RESISTANCE, 11 24 42 253 258 265

V VACUUM FORMING, 286 VALVE, 15 18 23 40 41 56 75 140 244 252 270 VALVE GATE, 4 186 191 240 VEGETABLE PACKAGING, 238 VEHICLE BONNET, 48 VEHICLE BOOT, 315 VEHICLE DOOR, 99 200 218 238 247 293 315 VEHICLE FASCIA, 70 257 VEHICLE GRILLE, 11 VEHICLE INTERIOR, 337 VEHICLE LIGHT, 80 127 137 165 167 179 209 211 227 239 247 326 339 372 375 VEHICLE RADIATOR, 11 VEHICLE SHELL, 11 80 204 246

315 VEHICLE TRIM, 1 109 134 257 324 330 351 354 VEHICLE WINDOW, 103 VEHICLE WING, 246 VENTILATION, 212 284 307 VERTICAL, 27 88 271 VERTICAL MACHINE, 3 18 29 35 55 75 101 122 140 141 142 146 194 199 247 363 VIBRATION DAMPING, 211 266 VIBRATION MOUNTING, 307 VISCOSITY, 2 50 78 92 115 149 159 205 218 239 266 270 282 290 316 324 332 334 355 VISUAL DISPLAY UNIT, 380 VOLUME, 4 81 161 VOLUME CONTRACTION, 44 VULCANISATE, 16 85 89 VULCANISATION, 16 51 55 125 151 307 363 VULCANISATION TIME, 43 51 55 108 121

W WALL THICKNESS, 2 5 11 76 85 105 114 126 135 149 151 212 259 274 283 298 308 311 354 WARPAGE, 49 76 149 211 334 WASHING MACHINE, 2 119 WATER-ASSISTED INJECTION MOULDING, 2 34 35 WATER PUMP, 304 WATER-SOLUBLE, 377 WEAR RESISTANCE, 42 51 159 266 271 WEATHER RESISTANCE, 103 112 253 WEIGHT, 238 244 291 332 WEIGHT REDUCTION, 2 11 19 42 63 158 247 303 312 359 374 WELD LINE, 2 4 17 149 164 268 280 316 317 323 325 333 334 355 WELDING, 158 196 198 302 WHEEL, 141 212 266 284 369 375 WHEEL COVER, 324 WHEEL TRIM, 316 WINDOW, 85 306 325 WINDSCREEN, 103 WINDSCREEN WIPER, 212 WIRE, 6 40

X X-RAY CONTRAST MATERIAL, 159

© Copyright 2002 Rapra Technology Limited

DOCUMENTS DIRECT (Document Delivery Service) The Polymer Library (www.polymerlibrary.com) is the world’s most comprehensive collection of information on the rubber, plastics, composites and adhesives industries. The fully searchable database covers approximately 500 regular journals as well as conference proceedings, reports, books, company brochures and data sheets. Almost all the articles selected for the database can be ordered in full text through our document delivery department. Non-patent requests are usually despatched within 24 hours of receipt (Monday to Friday). ●

We have a large collection of literature directly related to the industries we serve and can offer a personal service with minimal bureaucracy, based on detailed knowledge of our stock.

●

Many of the documents held at Rapra are not available via other services. This is particularly the case for our extensive and unique collection of company literature and data sheets.

●

We offer a fast turnaround service (within one working day) combined with a range of delivery options. Some full text documents are available as PDF files which can be downloaded immediately

SPEED OF DELIVERY Non-patent documents are despatched from Rapra within 24 hours of receipt (Monday - Friday) of request using first class mail within the UK, and airmail for the rest of the world. If you request e-mail or fax service, delivery will be within hours anywhere in the world.

HOW TO ORDER Orders can be made by post, fax, telephone, e-mail, on-line via the website database (http://www.polymerlibrary.com), or through an online host. When ordering please include your full company details and which documents you require, quoting one of the following: 1. Accession Number or Copyquest number or, 2. Full Bibliographic Details Please include which payment method you wish to use and how you wish to receive the article (i.e. e-mail, post, fax, etc.) Documents can be ordered from Rapra online using the appropriate command of your online host. In this case we will issue you with an invoice and statement every three months. For further information, please see www.rapra.net/absdocs/copyquest.htm or contact Sheila Cheese or Jackie McCarthy on +44 (0)1939 250383 or e-mail [email protected].

PLEASE TURN OVER FOR PAYMENT METHOD OPTIONS AND ORDER FORM

CREDIT CARD PAYMENTS This is preferable for people who only intend to use our service occasionally. The prices are per copy inclusive of postage and packaging if appropriate. Pre-payment is required by Credit Card payment. Delivery Method

Price

E-mail, Ariel, Fax, First Class / Airmail Post

£10 / Approx. US$15 or €17 (UK & Overseas) + VAT

PDF files

Prices – Please refer to online order form for details (these may vary – each publisher sets price)

ANNUAL DEPOSIT ACCOUNTS A more cost effective way to use our service is to open an annual deposit account. (Web subscribers can use their web subscription for both web access and document delivery) The minimum amount required to open an account is £200 / Approx. US$290 or €330 (UK & Overseas) Delivery Method

Price

E-mail, Ariel, Fax, First Class / Airmail Post

Documents are only priced at £7 / Approx. US$10 or €12 per item

PDF files

Prices – Please refer to online order form for details (these may vary – each publisher sets price)

Please Note: Any money remaining in an annual deposit account after 12 months is void. Patents are charged at a standard price of £10 / Approx. US$15 or €17.

ORDER FORM ❑ ❑

I would like to open/renew a deposit account for the following amount ___________________________________ I would like to order the following documents _______________________________________________________ _____________________________________________________________________________________________

PAYMENT Name: ____________________________________________________ Company: _________________________________________________ Address: __________________________________________________ _________________________________________________________ _________________________________________________________ Postcode: ______________________ Country: __________________ Telephone: _____________________ Fax: ______________________

❑ Remittance enclosed

(use only for opening or renewing annual deposit accounts)

(If paying by cheque, please make payable to Rapra Technology Ltd. in £ Sterling/US$/Euros via UK banks only or make payment direct to Account No: 05625025, Sortcode: 55-50-05, National Westminster Bank Plc, 8 Mardol Head, Shrewsbury, Shropshire, SY1 1HE, UK)

❑ Please invoice my company (use only for opening or renewing annual deposit accounts)

❑ Please deduct from my annual deposit account (use this option when ordering documents if you already have a deposit account)

IMPORTANT - Value Added Tax (VAT) The above prices do not include VAT. Customers in EU member countries may be liable to pay VAT if their Registration Number is not supplied. Please enter your EU Registration Number (VAT - BTW - IVA - TVA - MWST - MOMS - FPA) below:

VAT Number: Rapra Technology Limited Shawbury, Shrewsbury, Shropshire SY4 4NR, United Kingdom Tel. +44 (0)1939 250383 Fax: +44 (0)1939 251118 E-mail: [email protected]

Account Number _______________________________________

❑ Please charge my credit card American Express / Visa / Mastercard (delete as appropriate) Card Number:

Signature: ______________________ Exp. date: ______________