Injection mouldingand Composites Expertise and Innovation school presentations... · Injection...

Injection moulding and CompositesExpertise and Innovation

EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE

Innovation

Overview of Heat&Cool technologies

ALPLASTICSStéphane DESSORS 09/07/2013

Contents

PEP presentation

Why do we have to use Heat&Cool technologies ?

Convection

Radiation

Conduction


Conduction

Induction

Conformal cooling

Page /2 / 65

1. PEP

presentation

2. Why do we

have to use

Heat&Cool

technologies

3. Convection

4. Radiation

5. Conduction

6. Induction

7. Conformal

cooling

PEP presentation

EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIEPage /3 / 65

KEY WORDS

Technical and Innovation Centre in Plastics and compositesAssociation Act 1901 – founded in 1989Expert in thermoplastics injectionExpert in compositesApproved Crédit Impôt Recherche (CIR)Certified ISO 9001 - V2008

Goal : Improvement of the competitivity of national industry thanks to innovation

INJECTION MOULDING and COMPOSITES EXPERTISE


and collaborative platforms.

Strategy : Mutualized research.Platforms.

75 employees (researchers, engineers, technicians)

Annual sales 2012 : 8 M€ (including COMPOSITEC)50 % Research & Developpment (contract or collaborative)50 % business services

Year Employees Services Turnover

2007 45 1,9 M € 4,2 M €

2008 50 2,4 M € 4,8 M €

2009 46 1,8 M € 4,6 M €

2010 48 2,6 M € 5,9 M €

2011 55 3 M € 6,3 M €

2012 55 3,5 M € 6,7 M €

Page /4 / 65

5 BUSINESS UNITS

KEY WORDSINJECTION MOULDING and COMPOSITES

EXPERTISE


5 R&D axisAdvanced toolsHybrid productsOptimal designPolymers recyclingMicrosystems on plastic

Page /5 / 65

CUSTOMERS &

MARKETS

30%

5%

22%

MARKET SHARE

AUTOMOTIVE

AERONAUTIC / ARMY

MEDICAL

PACKAGING


20%10%

8%PACKAGING

CONNECTIC

OTHERS

Page /6 / 65

NETWORK&

PARTNERS

PEP in the heart of a European network :

French partners :


European partners : R&D centres in plastic and tooling partners

Protection of innovation :

PEP files patents every year

Page /7 / 65

BU Tools & Processes

EXPERTISE ET INNOVATION TECHNOLOGIQUE EN PLASTURGIE Page /8 / 65

EQUIPMENTSBU Tools & Processes

PLAteforme d’INNovation Outillage

11 injection moulding machines from 15t to 2200t

Technological solutions :• Injection of multi materials up to 1000T• LSR injection (mono or bi material)• Injection sandwich• Injection compression


• Injection compression• Heat&Cool (ROCTOOL, GWK…)• Injection with gas• Replication of micro and nano features

2 machines for laser fusion of metal powders1 HSM 5 axisPrograms of research and innovationIn partnership with CETIM

Platinno : L’Europe s’engage en Rhône-Alpes avec le FEDER

Page /9 / 65

Technologies :

EQUIPMENTSBU Tools & Processes

SMC / BMC compression mouldingContinuous fibre reinforced thermoplastic composites thermo compression


Moyens :

50T compression press400T compression pressInfrared oven (T° up to 400°C -(plies dimensions up to 1000 x 1000)FRTP thermo compression mouldsPlate moulds (170 x170 et 500 x 500) equipped with in-mould sensors (pressure, temperature, heat flow)« Reactivity cell » for in-situ cure monitoring

Page /10 / 65

KNOWLEDGE

Services proposed by the BU POA team of 20 engineers and technicians :

Injection trials and tuning phase of injection tools :• Optimization of cycle times• Pre-serial parts

Expertise of unstabilized processInstrumentation and Process control (press, tools, peripheral equipments)Design and realization of metallic blocks made by laser sintering

BU Tools & Processes


Design and realization of metallic blocks made by laser sintering technology (thermal optimization of the mould)

R&D programs : Thermal optimization of the moulds (conformal cooling, Heat&Cool, induction, etc.)Integration of functionalities in the tools (decoration, assembling, etc.)Surface treatments of the cavitiesInstrumentation of the tools

Page /11 / 65

Focus :Conformal Cooling


1 team with 8 engineers and technicians dedicated to thermal optimization

Page /12 / 65

CONFORMALCOOLINGFocus : Conformal cooling

Goals :Reduction of cycle timesReduction of the tuning phase schedule (homogeneous temperature)Improvement of the quality of the parts

Technology :Laser used for the fusion of metallic powders (particle size 30µ)Produced layer by layer (0.04 mm)


Characteristics of Maraging steel ( ≈ Z38CDV5) :Hardness : 37 to 54 HRC after hardening.Density : 99,8 %

Methodology :1. CAD – Thermal studies with SIGMA 3D : optimal design of the channels2. Fluidic studies with FLOWORKS3. Laser sintering technology to make metallic blocks4. Finishing with HSM 5 axis5. Validation of the flow rates and thermal properties6. Thermal treatment (hardening)

Page /13 / 65

M COOLM COOL

Optimization process with MCOOL® (PEP Patent) :

– Definition of the optimal surface for mould regulation

– 2 goals :

• Plastic material must be frozen according the cycle time defined by MOLDTHERM® (PEP patent)

• Homogeneous cooling

Design of the cooling channels:


Optimized regulationsurface

Design of the cooling channels:

Consideration of the volume of the mould and kinematicsConsideration of hydraulic properties (pressure losses)

Optimized regulationStandard regulation

Page /14 / 65

Business Unit Design & Simulation


EQUIPMENTSBU Design & Simulation

A team with 12 Doctors and engineers,several softwares dedicated to parts and moulds desi gn


DESIGN

- CATIA

- SOLIDWORKS

DESIGN

- CATIA

- SOLIDWORKS

RHEOLOGY

- MOLDFLOW

- SIGMA 3D

RHEOLOGY

- MOLDFLOW

- SIGMA 3D

OPTIMIZATION

- ANSYS

- MODEFRONTIER

- OPTISTRUCT

OPTIMIZATION

- ANSYS

- MODEFRONTIER

- OPTISTRUCT

Page /16 / 65

SERVICESBU Design & Simulation

Pré-studyPré-study

Preliminary designPreliminary design

Part/Process designPart/Process design


Part/Process designPart/Process design

Support for the tools and equipments manufacturingSupport for the tools and

equipments manufacturing

Tunings of production facilitiesTunings of production facilities

Transfer of the production facilities

Transfer of the production facilities

Page /17 / 65

BU Materials


EQUIPMENTS

Laboratory analysis and characterisation: Rheological (capillary rheometer, MFI, viscosity in solution)Mechanical (dynamometer, hardness tester, DMA…)Physico-chemical ( µFTIR, SEM,..)Aging (thermal, UV, climatic)Thermal (HDT, VICAT, DSC, ATG)Optical (microscope, brightness and colour measurements..)Flammability (FMVSS, UL94)Preparation of samples

BU Matériaux

• Pellets• Samples• Parts and products


Preparation of samplesSelf Approval RENAULT

Twin-screw compounder

Injection moulds with sensors (15)

A team of 9 experts : polymers, composites, characterisation, biomaterials, compounding

Materials database : RAPRA, Prospector Pro

Page /19 / 65

KNOWLEDGE

Services from BU MAT

Choice of materials :Research or substitution of materialsComparison of materialsValidation of specificationsBiopolymers

Testing, analysis or characterisations

BU Matériaux


Testing, analysis or characterisations

Production control (composites)

Establishment of data sheets

Quality control and material expertise

Formulation – compounding – injection – characterisation – analysis Polymer recycling, co-productLoad integration, reinforcements

Page /20 / 65

BU Plastronics :Smart Plastic Products


Le PEP est membre du GIXEL

Page /21 / 65

EQUIPMENTS

Equipments in PEP :Laser activation with LPKF-LDS Microline 3DPrototype plating line for electroless copper, nickel and goldCharacterization, tests and qualification: metrology and X-rays fluorescence for thickness control, other propertiesA team of 7 experts : design, injection moulding, electronics and MID (Moulded Interconnect Device)

BU Plastronics


Technological partners : LPKF, Dow, RTP, Häcker, Samaro, Acxys, ACP, HSG-IMAT, CEA, CSEM, MIND, IMECKey partnerships and European network: « 3D-MID » et « 4M »

Page /22 / 65

KNOWLEDGE

Micro- and nano- replication of functional features :

Pilot injection moulding platform with all required facilities for micro-/nano- replication

100% electrical injection moulding machine, 200T, bi-materialCompression moduleVacuum in the cavityHeat&Cool technologies to heat the cavities : Roctool, GWKOn line Plasma surface activation : AcxysOn line CO2 cleaning : ACP

BU Plastronics


On line CO2 cleaning : ACPOn line metrology control : ZeissAll the tasks in the injection cell are automatic thanks to a 6 axes robot from Stäubli

Exemples of functionalities proposed by micro- nano- r eplication on plastic parts:

Optic, embellishment and security / anti counterfeitingMicro fluidic : channels, filters, valves, anti-adhesion, diaphragmMicro mecanic / MEMS

Page /23 / 65

KNOWLEDGE

Design and realization of 3D-MID (Moulded Interconnect Devices) :

Goals :Adding functionalities to plastic parts (electrical connexions)Miniaturization and reduction of the number of components3D designReduction of the weightReliability of the function

BU Plastronics

Cré

dit :

Cas

sidi

an,

Fic

osa,

MIN

D, T

BI,

Rad

iall


Functions :Sensors, antenna, 3D wiring, connectors,lighting/signalisation, shielding, heat dissipation

Cré

dit :

Cas

sidi

an,

Page /24 / 65

LDS®-LPKFFocus

Thermoplastic Injection

Laser activation Chemical copper

Chemical gold deposition

Chemical nickel deposition

Chips assembly (CMS, flip-chip)


Injection copper deposition

depositiondeposition

Page /25 / 65

LDS®-LPKFFocus


Without MID With MIDSource kromberg & schubert

Page /26 / 65

LDS®-LPKFMID examples

Source Bosch

Source TBI - ABAXX


Source Harting

Source Panasonic

Page /27 / 65

Technological Watch and Competitive Intelligence


Competitive Intelligence Centre

Page /28 / 65

EQUIPMENTS

Specific documentation centre for Plastic industry

Access to data bases :• RAPRA• Thomson Innovation • Dialog (more than 500 data bases)• SPE

Technological watch and competitive intelligence centre


• SPE

Specialist of the Technical and Scientific Information

Plasturgienet• Data base with more than 6 000 references• Free access codes• www.plasturgienet.com

Page /29 / 65

Why do we

have to use

1. PEP

presentation

2. Why do we

have to use

Heat&Cool

technologies

3. Convection

4. Radiation

5. Conduction

6. Induction

7. Conformal

cooling


have to use

Heat&Cool

technologies ?

Page /30 / 65

HEAT & COOL


Heating the cavities to improve the filling

Cooling the mould to decrease the cooling time


HEAT & COOL


Why do we inject in a warm mould ?

Filling length

Brightness / Darkness

Welding linesreduced

Better replication (grain,micro- and

nano- features…)


Thin walls

Filling length

Better aspectwith materialsincluding fibres

Better holdingpressure (no sink mark)

Reduction ofinternal stress

(dimensional stability)

Reduction of thefrozen skin (mechanical

properties)

Page /32 / 65

HEAT & COOLWhy do we have to use Heat&Cool technologies ?

Reduction of the frozen layer


Cage system ® de RocTool

Simulation of the frozen layer without induction (left) and with induction (right)

Page /33 / 65


Reduction of internal stress in the part



Pictures made with polarized lens without induction (left) and with induction (right)

Page /34 / 65

HEAT & COOL


Brightness of the part in polished area

Without Cage system

With Cage system

Ra value for 5 different polymers



Brightness of the part in polished area

Brightness of the part in grained area

Rz value for 5 different polymers

Page /35 / 65



Pressure measurements in the cavity, in 3 areas, with and

without Cage system


Page /36 / 65

HEAT & COOL


Fibres marks removed thanks to Heat&Cool



Parts injected with PP loaded with long glass fibres, without induction (left) and

with induction (right)

Page /37 / 65

HEAT & COOL


Dimensional stability highly improved



Dimensions deviations from nominal size

(in percentage), without induction (blue)

and with induction (red)

Deviations of the dimensions due to

thermal cycles (in percentage), without

induction (pink) and with induction (red)

Page /38 / 65

HEAT & COOL


Dimensional stability highly improved



Standard deviation of the process in percentage, without induction

(blue) and with induction (red), for ABS (left) and for PEHD (right)

Page /39 / 65

HEAT & COOL


Improvement of the mechanical properties



Charpy test for several polymers, with and without induction, in the

longitudinal direction (blue) or transverse direction (red)

Page /40 / 65

HEAT & COOL


Improvement of the mechanical properties



Pulling module for several polymers, with and without induction, in

the longitudinal direction (blue) or transverse direction (red)

Page /41 / 65

HEAT & COOL


Technology required for micro

and nano replication


Influence of mould temperature

Page /42 / 65

HEAT & COOL

Convection

4 different kind of technologies :

Convection

Heating with water or oil

Heating with steam

Heating with pressurized water

Heating with hot air

Radiation


Radiation

Conduction

Induction

Page /43 / 65

HEAT & COOL

Convection

Heating technologies based on convection

phenomenon

Thermoregulation with water : < 95°C

Thermoregulation with pressurized water : < 200°C

Thermoregulation with oil : < 350°C


HEAT & COOL

Convection

Variotherm

2 fluids are required (1 hot fluid and 1 cold fluid)

Either 1 channel or 2 seperate channels

Electro valve to switch from the heating to the cooling, or

from the cooling to the heating


HEAT & COOL

Convection

Variotherm BFMOLDTM from Wittmann/Battenfeld

(developed by Kunststoff Institut from Ludenscheid)

Metallic balls are placed behind the surface of the cavity

Balls are able to support high pressure and reduce the volume of steel

� better efficiency


� better efficiency

Page /46 / 65

HEAT & COOL

Convection

Heating with steam

RHCM: Rapid Heat Cycle Molding

(Ono Sangyo Co and Sabic Innovative Plastics)

RTCTM: Rapid Temperature Cycling

(distributed by F.I.T. in Oyonnax)


HEAT & COOL

Convection

Heating with steam

Advantages:

Same channels in the mould for

heating and cooling

Steam is recycled

Drawbacks:


Drawbacks:

Maximal mould temperature is

180°C

Optimized cooling is highly

recommended (conformal

cooling)

Page /48 / 65

HEAT & COOL

Convection

High pressurized water

Advantages:

Same channels in the mould for heating and cooling, very

easy to set up

Possibility to use it as curative solution

Low energy consumption


Drawbacks:

Maximal mould temperature is 190°C

Optimized cooling is highly recommended (conformal cooling)

Page /49 / 65

HEAT & COOL

Radiation


Convection

Radiation

Infra-Red radiation

Heating with electrical or gas supply


Heating with electrical or gas supply

Conduction

Induction

Page /50 / 65

HEAT & COOL

Radiation

Infra-Red radiations

Wavelength: 800 to 3000 nm


HEAT & COOL

Conduction


Convection

Radiation


Conduction

Quick heating with mice or ceramic components

Heating with electrical cartridges

Induction

Page /52 / 65

HEAT & COOL

Conduction

Strato conception + conformal cooling

Cavities are made with 3 metallic blocks

Heating component is placed between the 2 superior plates

Conformed channels are drilled in the inferior plate

Assembling of the blocks with a brazing process


Only 1 screen to manage the heating and the cooling

Page /53 / 65

HEAT & COOL

Conduction

Strato conception + conformal cooling


HEAT & COOL

Induction


Convection

Radiation


Conduction

Induction

External induction

Induction integrated in the mould

• Cage system®

• 3iTech®

Page /55 / 65

HEAT & COOL

Induction

RTCTM IHC from GIWW

Inductor coil fixed on a slide under the mould


HEAT & COOL

Induction

Inductor coil fixed on the handler

Almost no specifications for the mould

Easy set up in the workshop

Possibility to use it as a curative solution


HEAT & COOL

Induction

Cage system® from RocTool

Electrical loops around the mould (gap of several millimeters)

Cavity heating on the surface (Joule effect on both sides of the

mould)


Example of cavity heating

for a 500x600mm part:

between 6°C/s and 10°C/S

Page /58 / 65

HEAT & COOL

Induction

Cage system® from RocTool


HEAT & COOL

Induction

3iTech® from RocTool

Inductor coils integrated in the cavity block

Possibility to heat the cavity even when the mould is closed


HEAT & COOL

Induction

3iTech ® de RocTool

3iTech® from RocTool


HEAT & COOL

Cooling

Conformal cooling

Laser sintering technology with metallic powders

highly recommended to combine this technology with a heating solution:

to have better efficiency

to reduce cycle times

to improve the quality of the parts


to improve the quality of the parts

Page /62 / 65

HEAT & COOL

Cooling

Refroidissement au gaz carbonique

Cooling with CO2

Technology based on CO2 change of phase (liquid ↔ gas)


HEAT & COOL

Conclusion

Best results are achieved when Heating and cooling technologies are

combined

Lots of parameters must be considered to evaluate what is the best solution:

Temperature that has to be reached

Cycle time and batch size


Cycle time and batch size

Design of the part

Part price / Investments

PEP’s experience is helpful if you have to optimize a process with a

Heat&Cool technology

Page /64 / 65

HEAT & COOL

Conclusion

Thank you

Feel free to ask questions


Feel free to ask questions

Stéphane DESSORS

[email protected]

+33 (0) 4 74 81 92 80Page /65 / 65

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