Why Water- Assisted Injection Moulding?
Advantages and Equipment
Dipl- Ing. Wolfgang Roth Gas- and Water- Assisted Injection Moulding 19th. and 20th. September 2007 Warwick University, Coventry
Water- Assisted Injection Moulding
The process of water- assisted injection moulding was developed at the Institut fr Kunststoffverarbeitung (IKV) of the University in Aachen, Germany. Aquamould is based on the developments and experiences of the IKV, where Battenfeld have a close cooperation.
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
Aquamould
What are the advantages of water? Low cost media No remaining ingrediants of water in mouldings Water is incompressible Direct internal cooling of mouldings
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
Aquamould
Nitrogen 1 bar, 20 C Thermal conductivity [W/m K] Specific heat capacity cp [J/kg K] Water 1 bar, 20 C
0,0143
0,604
> Factor 40
1038
4182
Reference: IKV Aachen
> Factor 4
Advantages:
Battenfeld Spritzgietechnik
Reduced cooling times compared to gas- assisted injection moulding
Water- Assisted Injection Moulding
Aquamould
Tube, 10 mm diameter Surface temperature after demoulding Photo taken by infrared camera With Aquamould: Shorter cooling times
Gas Airmould
Battenfeld Spritzgietechnik
Water Aquamould
Water- Assisted Injection Moulding
Process variants:
Short-shot process Back to screw process Overflow process
Limitation: Water injection through machine nozzle is not possible.
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould Advantage:
Smooth surface of internal channels
Body side panel
Battenfeld Spritzgietechnik
Arm rest, thick wall
Water- Assisted Injection Moulding Aquamould Advantage:
Even wall thickness distribution
Pipe, 10 mm diameter, PA 6
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould Advantages:
Large diameters with even wall thickness distribution
Tube
Polymer: PP Diameter: 60 mm
More even residual wall thickness due to internal cooling by water
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould Advantage:
Can be also used for large wall thickness Media ducts with functional elements, ABS Wall thickness: 2- 20 mm
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould Advantages:
Suitable for large wall thickness Tube with V- Connection
TPE
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Water- Assisted Injection Moulding Aquamould Advantages: Suitable for long flow paths Test mould
Length: 3.000 mm Polymer: PS Advantage: Even channel diameter over full length of moulding Quelle: IKV Aachen
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Moulding suitable for Aquamould: Aesthetic products High aesthetic requirements for surface quality
Functional products High requirements for interior surface quality
Examples Grab handles Toys Thick wall products ...
Examples Tubes and pipes Media ducts ...
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
- Economical and innovative process - No competition to Airmould - an additional process - Competiton to 3-D blow moulding - Suitable for a large range of polymers (PP, PA, ABS, PBT, PA-GF, TPE, etc.)
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Water injection
Water nozzle
Shut- off nozzle Water injection and exit
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
How to get the water out of the moulding? By gravity Blow out by compressed air at a remote position Injection of compressed air through water nozzle Use of vacuum
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
The Aquamould Modular System: Pressure generating systems for water, series WE Mobile control cabinet Pressure control modules Nozzles for water injection
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Pressure generating systems for water, Series WE: Accumulator for high water flow: > 1 l/s One WE unit can serve 2 injection machines
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Pressure generating systems for water, series WE: Accumulator for high water flow: > 1 l/s One WE unit can serve 2 injection units
Pressure generating unit for Water: WE 100
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Mobile control cabinet Unilog B 4 AC Same interface for Airmould and Aquamould: Euromap 62
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Pressure control modules for water
Precise pressure build- up Leak free valves
Connection via electrical supply only
Small compact units
Can be positioned close to the mould
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Requirements for water injection nozzles (water injectors): Small dimensions Large diameters for increased water flow Active opening and closing functions Leak free Easy installation
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
Water injection nozzles: Excellent separation between water and oil Proximity switches for stroke control Easy installation
Water in/out Hydraulic: nozzle close Drain port Hydraulic: nozzle opening
Battenfeld Spritzgietechnik
Connection to electronic control
Water- Assisted Injection Moulding Aquamould
Example: Water nozzle injecting direct into the mould cavity
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding How to get the water out of the moulding?
By gravity 1 injector is sufficient Alternating injection of compressed air through water injector 1 injector sufficient Evacuation 1 injector sufficient Blow out by compressed air at a remote position 2 injectors required (additional air injection)
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
Electronic control and measuring device for wall thickness
Pressure control module mounted beneth the mould
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Water- Assisted Injection Moulding Combination of Processes Multifoam Process:
Water- assisted injection moulding with Co- injection Cross section of media duct: Skin: PA 66, 30% GF Core: PP 20% GF Hollow section formed with Aquamould
Battenfeld Spritzgietechnik
Quelle: IKV Aachen, Schukmann
Water- Assisted Injection Moulding Co- injection Technology
Machine Technology
HM 270/1330 H/ 1000 H Unilog B 6
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Water- Assisted Injection Moulding Multifoam Process
Combination of mechanical strength and chemical resistance
Cross section of media duct Skin: PA 66, 30% GF Core: PP 20% GF Hollow section formed with Aquamould
Battenfeld Spritzgietechnik
Quelle: A. Schulmann
Water- Assisted Injection Moulding Combination of Processes
Multi- component injection moulding and Aquamould
Soft ball racket Frame, PP, grade 1 Hollow section by Aquamould Contact area, PP, grade 2 Advantages: Strong and light frame with hollow section Short cycle time by direct internal water cooling
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Combination of Processes
Multi- component injection moulding and Aquamould TM 2100/ 1000+ 525 S with Aquamould Pressure generating unit WE Mobile control cabinet with pressure control module for water
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Three wheel bike for kids: Handle- bar and fork, PP
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Water- Assisted Injection Moulding Aquamould
Three wheel bike for kids: Handle- bar and fork, PP
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Clutch pedal, VW: Aquamould clutch pedal replaces hybrid solution: PA 6 GF 30 GF 30 Right: Metal insert, overmoulded with PA 6 GF 30 Middle and left: All plastic solution with Aquamould
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
The Start Steel insert app. 200g Plastic (PA GF30) app. 200g
Hybrid moulding
= 400 g
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
The Target Vehicle weight reduction
Cost reduction (Cycle time and production cost)
Reduction of processing steps
Improved recycling possibilities
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
The Solution All Plastic Moulding (PA6 GF30) using short shot process ca. 200g By water- assisted injection moulding
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
The Solution All Plastic Moulding (PA6 GF30) using short shot process ca. 200g By water- assisted injection moulding
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
The Process
Injection of polymer (Melt pre- filling) Ultrasonic sensor
Water injection (complete filling of cavity) Water release Measuring of residual wall thickness by Ultrasonics Ejection of moulding
Battenfeld Spritzgietechnik
Wasserinjektor Water nozzle
Good
Bad
Injection Spritzeinheit unit
Quelle: Entwicklung 3-PBP-2/2
Water- Assisted Injection Moulding
The Results
Cost reduction app. 10%
Weight reduction app. 50%
Cycle time reduction app. 30%
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding
Now see a video sequence of the clutch pedal production
Battenfeld Spritzgietechnik
Water- Assisted Injection Moulding Aquamould
Handle for car seat adjustment: PA 6 GF 30, produced by Aquamould:
Battenfeld Spritzgietechnik
Why Water- Assisted Injection Moulding?
Advantages and Equipment
Dipl- Ing. Wolfgang Roth Gas- and Water- Assisted Injection Moulding 19th. and 20th. September 2007 Warwick University, Coventry