Page 61 - Plastics News February 2024

IN THE NEWS

sisted and, in the future, autonomous plastic sheet.
driving. To make sure that the sensors The first high-volume production ap-
also work reliably in the winter, BMW plication of this technology went live
back-injects a heatable functional film in 2018 at Valeo Front End Modules
with polycarbonate, which is then in Smyrna, Tennessee, USA. Start-
flood-coated with polyurethane. Fol- ing with thermoplastic sheets, Valeo
lowing several applications for the Front End Modules manufactures
vehicle interior, this is the first time front end carriers with integrated air
that BMW is using a combination of ducts for a German brand name OEM
film back-injection and flood-coating at its plant. The systems solution sup-
in the series production of functional New mobility applications sometimes plied by ENGEL for automated high
parts on the exterior, where they are require particularly large injection volume production consists of an EN-
exposed to particularly high stress. moulding machines. ENGEL builds GEL duo 1700 injection moulding ma-
The sensitive electronics are well mega machines with clamping forces chine, three ENGEL easix articulated
protected under the scratch-resistant of more than 10,000 tonnes robots for preparing large quantities
polyurethane surface. The high gloss of metal inserts and for handling the
level and depth effect, which even a Lightweight plays a central role in thermoplastic sheet, an ENGEL vi-
thin coating of polyurethane achieves, achieving climate protection targets. per 90 linear robot and an ENGEL IR
convey a very elegant impression. At its own interdisciplinary technol- oven.
ENGEL is the system supplier for this ogy centre for lightweight composites
demanding project. The production at the St. Valentin production plant in The double-shell structure made it
cell integrates an ENGEL duo combi Austria, ENGEL has been developing possible to integrate the air ducts di-
M injection moulding machine with a innovative composite solutions in co- rectly into the carrier structure. The
horizontal rotary table, two large ar- operation with partner companies for two half-shells are produced in a
ticulated robots for handling the films more than ten years. The primary de- one-shot process. To do this, the two
and moulded parts, a film cleaning velopment goal is integrated and au- thermoplastic sheets are simultane-
system, an inline quality-control sta- tomated processes for cost-efficient ously heated in the IR oven, and then
tion and peripheral units including the high-volume production. inserted into the mould, where they
polyurethane feed. One focus of the development work are formed and functionalised.
ENGEL is collaborating with devel- is on the use of thermoplastic fibre Fuel cells drive innovation
opment partners in the field of com- composite materials. “The reasons Alternative drive technologies are also
bined back-injection and PUR flood- for this are the highly efficient pro- opening up new potential for the in-
coating, including Leonhard Kurz cesses for processing thermoplastics jection moulding industry. "Hydrogen
Stiftung, Schöfer and Votteler Lack- on the one hand, and greater sustain- technology is currently being pro-
fabrik. In the scope of a project study, ability on the other”, says Füreder. An moted particularly strongly in Europe,
the partner companies were able to approach which consistently relies on especially in the truck sector," as Fis-
demonstrate that flood-coating with thermoplastic material paves the way cher reported. "The Cellcentric joint
polyurethane, which is equivalent to for recycling the parts later on. venture sees Daimler Truck and the
in-mould painting in terms of the pro- In the ENGEL organomelt pro- Volvo Group bundle their experience
cess, accounts for only 20 percent of cess, thermoplastic fibre composite in the development and production of
the total energy consumed in the pro- prepregs – for example, thermoplas- fuel cell systems, and they have cho-
duction process. This means that the tic sheets and UD-Tapes – are shaped sen ENGEL as one of their technology
integrated process offers significantly and functionalised in a single inte- suppliers."
improved energy-efficiency com- grated step. To achieve this function-
pared with painting the parts outside alisation, reinforcing ribs or assembly In particular, the expertise which EN-
of the injection moulding process. elements are moulded immediately in GEL has in processing elastomers and
Efficient lightweight composites the same mould after thermoforming liquid silicone rubber (LSR) is crucial
here. Fuel cells require many seals,
with thermoplastics using a thermoplastic from the same some of which are moulded directly
matrix material group as the thermo-

PLASTICS NEWS 63
February 2024