Products for automotive interior parts, manufacturers will use more and more decorative material with a polyurethane skin, high-quality finish, or functional coating of injection molding products. But the disadvantage is that such products are often complex and costly. However, the reaction injection molding (RIM) technology into the injection molding process to produce a new technology economy, this situation will change, so that the product is still closed when the mold can be carried out in the polyurethane coating. So that we can state in the closed mold coated with polyurethane to the parts, changing the previous situation to the savings goal.
In the system supplier fischer Automotive Systems Co., Ltd., Bayer MaterialScience and Krauss-Maffei Plastics Technology Co., Ltd. a joint development project between, through a prototype test the feasibility of the new process. Selected to test the product is luxury automobile cup holder decorative pieces. It can also use the conventional coating process, by fischer Automotive Systems production lines and about 1.5 mm thick coating of polyurethane coating. Polycarbonate from Bayer division, responsible for the development project is responsible for the commercial sector development projects Rainer Protte explained: "This combination proved that the modification of stylish and elegant appearance of the production is very promising technology."
Bayer MaterialScience developed the new technology started as a mold coating of a special form, which in the closed mold injection directly into the binary coating systems coating products. The process was later extended to the use of the products of polyurethane coatings. At the same time as the production is the production of polyurethane injection molding equipment and machinery, Krauss-Maffei Corporation, which developed the SkinForm process, the process in the first public appearance on the K2004 exhibition. Both methods can be classified as "direct method" - Polyurethane cortex "DirectSkinning" process and polyurethane coatings "DirectCoating" process. The two companies will be in the top of the experience of new technology and comprehensive fischer Automotive Systems, resulting in the joint development project.
Process described above is essentially based on dual injection molding, but instead of using thermoplastic material as the second component, which uses reactive polyurethane system, through the polyurethane mixing head directly to the material injected into the mold cavity. The first step is the beginning of the cavity in the thermoplastic injection molding, the mold opens, and then transferred to the second molding cavity products, you can use the parallel moving table, roulette wheel or a fixed rotation molding equipment to complete the action . Again closed mold, the use of reaction injection molding (RIM) process dual injection into the reaction system and the thermoplastic polyurethane surface curing reaction occurred immediately. When curing polyurethane system, you can use a fixed rotation of the wheel or molding equipment in the first mold cavity in the processing of the next product, which can shorten the cycle time to improve production efficiency.
New technology in the coating thickness, feel the surface properties and decorative aspects of processing a great deal. It to the form of solid or have thin foam polyurethane coating (= 1mm) or polyurethane to achieve a few mm cortical thickness.
Polyurethane cortex, new technology and processes than before, has great advantages in a single mold can produce products. Because they no longer need to use another mold cortex, the overall die cost reduction, but also reduce the logistics costs. Thin layer of thermoplastic material in the polyurethane coating, the new technology has the advantages of investment costs, logistics and space requirements are better than using a separate coating line is much lower. Will not need any injection molding products transferred to the coating plant and the possible need for intermediate storage. Since the last injection mold decoration completed directly, so there is no product in the application of coating when the risk of contaminated or damaged, this reduces the rejection rate. Another advantage of a separate coating application will not be over-spray problems.
Protte explained: "We see great potential for development of new technologies, especially in automotive interiors coated products, such as handrails, trim, door handles, the final modification of materials, automotive instrument panel compartment hinges, center console Its anti-tray. "Once the new technology is further developed, the door liner, instrument panel and other large components of the production is also achievable. Possible applications include body colored sash or a clear coating paint (dark) of the final modification of materials.
Bayer MaterialScience now the new DirectCoating and DirectSkinning / SkinForm process various raw materials used in the optimization. Protte said: "When customers work with us, they get a lot of convenience, we provide them with not only all the processing related to key technologies, and all required materials can be from a single vendor." This means that the customers can choose between a variety of carrier materials, such as Bayblend (PC + ABS), Makroblend (PC + PET or PC + PBT), Makrolon (PC) or Baydur (PU) and other materials. As for the implementation of the polyurethane coating raw materials Bayflex / Desmodur suitable material used to make Cortex, Desmophen / Desmodur for dual polyurethane coating. Through the use of aliphatic isocyanates as a raw material component, can be non-yellowing polyurethane coating Fast. Protte said: "We will continue to follow the trend, developing a bright, attractive color of car interior parts."
In the system supplier fischer Automotive Systems Co., Ltd., Bayer MaterialScience and Krauss-Maffei Plastics Technology Co., Ltd. a joint development project between, through a prototype test the feasibility of the new process. Selected to test the product is luxury automobile cup holder decorative pieces. It can also use the conventional coating process, by fischer Automotive Systems production lines and about 1.5 mm thick coating of polyurethane coating. Polycarbonate from Bayer division, responsible for the development project is responsible for the commercial sector development projects Rainer Protte explained: "This combination proved that the modification of stylish and elegant appearance of the production is very promising technology."
Bayer MaterialScience developed the new technology started as a mold coating of a special form, which in the closed mold injection directly into the binary coating systems coating products. The process was later extended to the use of the products of polyurethane coatings. At the same time as the production is the production of polyurethane injection molding equipment and machinery, Krauss-Maffei Corporation, which developed the SkinForm process, the process in the first public appearance on the K2004 exhibition. Both methods can be classified as "direct method" - Polyurethane cortex "DirectSkinning" process and polyurethane coatings "DirectCoating" process. The two companies will be in the top of the experience of new technology and comprehensive fischer Automotive Systems, resulting in the joint development project.
Process described above is essentially based on dual injection molding, but instead of using thermoplastic material as the second component, which uses reactive polyurethane system, through the polyurethane mixing head directly to the material injected into the mold cavity. The first step is the beginning of the cavity in the thermoplastic injection molding, the mold opens, and then transferred to the second molding cavity products, you can use the parallel moving table, roulette wheel or a fixed rotation molding equipment to complete the action . Again closed mold, the use of reaction injection molding (RIM) process dual injection into the reaction system and the thermoplastic polyurethane surface curing reaction occurred immediately. When curing polyurethane system, you can use a fixed rotation of the wheel or molding equipment in the first mold cavity in the processing of the next product, which can shorten the cycle time to improve production efficiency.
New technology in the coating thickness, feel the surface properties and decorative aspects of processing a great deal. It to the form of solid or have thin foam polyurethane coating (= 1mm) or polyurethane to achieve a few mm cortical thickness.
Polyurethane cortex, new technology and processes than before, has great advantages in a single mold can produce products. Because they no longer need to use another mold cortex, the overall die cost reduction, but also reduce the logistics costs. Thin layer of thermoplastic material in the polyurethane coating, the new technology has the advantages of investment costs, logistics and space requirements are better than using a separate coating line is much lower. Will not need any injection molding products transferred to the coating plant and the possible need for intermediate storage. Since the last injection mold decoration completed directly, so there is no product in the application of coating when the risk of contaminated or damaged, this reduces the rejection rate. Another advantage of a separate coating application will not be over-spray problems.
Protte explained: "We see great potential for development of new technologies, especially in automotive interiors coated products, such as handrails, trim, door handles, the final modification of materials, automotive instrument panel compartment hinges, center console Its anti-tray. "Once the new technology is further developed, the door liner, instrument panel and other large components of the production is also achievable. Possible applications include body colored sash or a clear coating paint (dark) of the final modification of materials.
Bayer MaterialScience now the new DirectCoating and DirectSkinning / SkinForm process various raw materials used in the optimization. Protte said: "When customers work with us, they get a lot of convenience, we provide them with not only all the processing related to key technologies, and all required materials can be from a single vendor." This means that the customers can choose between a variety of carrier materials, such as Bayblend (PC + ABS), Makroblend (PC + PET or PC + PBT), Makrolon (PC) or Baydur (PU) and other materials. As for the implementation of the polyurethane coating raw materials Bayflex / Desmodur suitable material used to make Cortex, Desmophen / Desmodur for dual polyurethane coating. Through the use of aliphatic isocyanates as a raw material component, can be non-yellowing polyurethane coating Fast. Protte said: "We will continue to follow the trend, developing a bright, attractive color of car interior parts."
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