decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back...
TRANSCRIPT
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Back Molding Technology
Decorated parts in one process step
![Page 2: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/2.jpg)
Back Molding Technology
Contents
1. Introduction
2. Decoration processes - overview
3. Technology for decoration with films
4. Technology for decoration with textiles
5. Special processes for decoration5.1 Back Molding with foamed material5.2 Sequential injection molding5.3 Compression injection molding
6. In Mold Labeling (IML)
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 3: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/3.jpg)
Back Molding Technology
Contents
1. Introduction
2. Decoration processes - overview
3. Technology for decoration with films
4. Technology for decoration with textiles
5. Special processes for decoration5.1 Back Molding with foamed material5.2 Sequential injection molding5.3 Compression injection molding
6. In Mold Labeling (IML)
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 4: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/4.jpg)
Motivation
Increasing of profitability by:
Integrated functions
Saving of the following process steps, e.g.printingpaintinglaminating
high level of automation
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 5: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/5.jpg)
Back Molding Technology
Contents
1. Introduction
2. Decoration processes - overview
3. Technology for decoration with films
4. Technology for decoration with textiles
5. Special processes for decoration5.1 Back Molding with foamed material5.2 Sequential injection molding5.3 Compression injection molding
6. In Mold Labeling (IML)
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 6: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/6.jpg)
Goal and way of solution
Completely decorated molding out of the injection molding machine
Back Molding of preformed printed films
Back Molding of printed carrier films
In Mold Decoration (IMD)
Back Molding of wood veneer
Back Molding of textiles
In Mold Labelling (IML)
Back Moulding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 7: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/7.jpg)
Decoration processes
Films:
In Mold Decoration (IMD) using embossing films
Film Insert Molding (FIM) using flat or preformed films
TPO Films
Textiles:
Trimming as a separate process outside the mold
In Mold Cutting (IMC) = textile cutting in the mold
Wood:
Veneer
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 8: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/8.jpg)
Back Molding Technology
Contents
1. Introduction
2. Decoration processes - overview
3. Technology for decoration with films
4. Technology for decoration with textiles
5. Special processes for decoration5.1 Back Molding with foamed material5.2 Sequential injection molding5.3 Compression injection molding
6. In Mold Labeling (IML)
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 9: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/9.jpg)
Back Molding Technology
Technolgy for Decoration with film
1. In Mold Decoration - IMD
2. Film Insert Molding - FIM
Flat film
Preformed film
TPO film
1. Backmolding of wood
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 10: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/10.jpg)
In-Mold-Decoration (IMD)
Principle:
Film feeding device transports decorated film in between two opened halfs of the mould
Back Molding of the film
Decoration relieves from the carrier film and fixes on the molding
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
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In-Mold-Decoration (IMD)
Film feeding device
Quelle/Source: Fa. Kurz
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 12: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/12.jpg)
In-Mold-Decoration (IMD)
IMD-Films:
single decorative film endless decorative film
/Vitalo/
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 13: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/13.jpg)
In-Mold-Decoration (IMD)
Principle design of the embossing film
Carrier layer
Separation layer
Scratch resistant layer
Decorative layer
Transfer layer
Direction of back molding
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 14: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/14.jpg)
In-Mold-Decoration (IMD)
Plastic
Visible site
construction for depth effect
Plastic
Visible site
Decorative layer
„normal“ construction
Process variable
Back Molding Technology
Decorative layer
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 15: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/15.jpg)
In-Mold-Decoration (IMD)
Metallic-pigments
Metallized areas
Brushed areas
Colour changing with temperature
Hologram
Special scratch resistant
Shielding effect
Multiple designs and functions
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 16: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/16.jpg)
In-Mold-Decoration (IMD)
Automotive
Telecommunication
Household and electronic
Cosmetics (Packaging)
Hifi
Leisure and sports
Applications :
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 17: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/17.jpg)
In-Mold-Decoration (IMD)
Quelle/Source: Fa. Kurz
Product code for cars
Application: Automotive
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 18: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/18.jpg)
In-Mold-Decoration (IMD)
Decorative molding
Cover
Application: Automotive
Quelle/Source: Fa. Kurz
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 19: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/19.jpg)
In-Mold-Decoration (IMD)
Cover for heater control
Application: Automotive
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 20: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/20.jpg)
In-Mold-Decoration (IMD)
Display for mobile phone
Application: Telecommunication
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 21: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/21.jpg)
In-Mold-Decoration (IMD)
Housing for mobile phones
Quelle/Source: Fa. Kurz
Back Molding Technology
Application: TelecommunicationFilm
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 22: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/22.jpg)
In-Mold-Decoration (IMD)
Household goods
Application: household /electronic
Quelle/Source: Fa. Kurz
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 23: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/23.jpg)
In-Mold-Decoration (IMD)
Back Molding Technology
Application: household /electronic
Household goodsFilm
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 24: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/24.jpg)
In-Mold-Decoration (IMD)
Electronic
Quelle/Source: Fa. Kurz
Back Molding Technology
Application: household /electronicFilm
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 25: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/25.jpg)
In-Mold-Decoration (IMD)
Quelle/Source: Fa. Kurz
Cover for loud speaker
Back Molding Technology
Application: household /electronicFilm
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 26: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/26.jpg)
In-Mold-Decoration (IMD)
Quelle/Source: Fa. Kurz
Aesthetic packaging
Application: Cosmetic
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 27: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/27.jpg)
In-Mold-Decoration (IMD)
2- and 4 - cavity molds possible
Direct gating with hotrunner
Positioning with printed brands
Tolerances at the molded part up to ± 0,02 mm
Closed loop control between film feeding device and optical sensor
Communication between film feeding device and IMM via interface
Mold technology and accessories
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 28: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/28.jpg)
In-Mold-Decoration (IMD)
high automation level
flexible in design and fast changing of decorative surface
no pre-treatment
no solvents
good adhesion on the substrate
decorative surface is able to cover welding lines
Advantage
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 29: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/29.jpg)
In-Mold-Decoration (IMD)
special moulds
heat resistance of the film must be higher than melt temperature
minimal number of pieces and timing for the production of the film
depth of the decorated surface is limited
radius are limited
cleaning of the parts might be necessary
Boundary conditions
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 30: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/30.jpg)
Film Insert Molding (FIM)
Principle:
more thicker and rigid film (painted or printed) is inserted in the mould
films are preformed or not and cutted
flat and 3 dimensional parts can be molded
film is part of the molded article
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 31: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/31.jpg)
Film Insert Molding (FIM)
Main applications:
automotive
telecommunication
medical technology
white goods
...
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 32: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/32.jpg)
Film Insert Molding (FIM) – flat films
Application: production of a tray
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 33: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/33.jpg)
Film Insert Molding (FIM) – flat films
System technology
film magazin
separation of films
mold
double gripperbuffer
hot stamping of the rim transport of finished parts
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 34: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/34.jpg)
Film Insert Molding (FIM) – flat films
System solution for back molding of films
Video:system solution
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 35: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/35.jpg)
Film Insert Molding (FIM) – flat films
cover for washing machine
Material: PMMA
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 36: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/36.jpg)
Film Insert Molding (FIM) – preformed films
process steps
Final partprecuttedfilm
preformedfilm
printedfilm
Quelle/Source: Fa. Kurz
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 37: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/37.jpg)
Film Insert Molding (FIM) – preformed film
Decoration of the film
silk screen printing
Off- set printing
colouring of the film
vacuum coating
scratch proof coated
PVD coated
Quelle/Source: Fa. Bayer
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 38: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/38.jpg)
Film Insert Molding (FIM) – preformed film
Preforming if the film
mechanical
hydraulic
thermoforming
preforming during back molding
high Pressure Forming (HPF)
High Pressure Forming
Quelle/Source: Fa. Bayer
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 39: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/39.jpg)
Film Insert Molding (FIM) – preformed film
Cutting
cutting with knifefor single samples
steel rule cutting diedepends on geometry for pilot plant production
cuttiing diefor mass production
Quelle/Source: Fa. Bayer
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 40: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/40.jpg)
Film Insert Molding (FIM) – preformed film
Insert and setting
insert manual with robot
settingcores in the moldejector systemsslide (clamp)pins out site the cavityvacuumelectrostatic loading
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 41: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/41.jpg)
Film Insert Molding (FIM) – preformed film
Requirements for robot
high precision with servo axes
suitable gripper cross head gripperturning double gripper
assembling of charging element
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 42: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/42.jpg)
double gripper with 3 triods
Film Insert Molding (FIM) – preformed film
Insert of preformed films
filmmagazin
charging generator
Tranport of finished parts
Quelle/Source: Fa. HAUG
triode
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 43: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/43.jpg)
Film Insert Molding (FIM) – preformed film
film
end product
Material: PCQuelle/Source: Fa. Bayer
Application: cover for heater controls
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 44: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/44.jpg)
Film Insert Molding (FIM) – preformed film
Application: cover for a car
Material: ABS + PC/ABS
Quelle/Source: Fa. Bayer
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 45: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/45.jpg)
Film Insert Molding (FIM) – preformed film
Preformed and cutted film
final partMaterial: ABS + PC/ABS
Quelle/Source: Fa. Bayer
Back Molding Technology
Application: cover for a carFilm
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 46: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/46.jpg)
Film Insert Molding (FIM) – preformed film
Application: side protector trim
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 47: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/47.jpg)
Film Insert Molding (FIM) – preformed film
production cell with HM 3500 / 2280 and KUKA KR 30
Back Molding Technology
Application: side protector trimFilm
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 48: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/48.jpg)
Film Insert Molding (FIM) – preformed film
precentering of film
clean room conditions
end parts
KUKA KR30/3
insert of filmremove final part
Back Molding Technology
Application: side protector trim
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 49: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/49.jpg)
Film Insert Molding (FIM) – preformed film
Requirements for the film
transparency
suitable for printing
elasticity for preforming
load-bearing capacity for cutting process
heat resistance
shrinkage behaviour
high surface quality
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 50: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/50.jpg)
Film Insert Molding (FIM) – preformed film
Advantages
fast changing of decorating
multiple possibilities for decorating
3-D geometry possible
no pre treatment
welding lines can be covered
protected printing
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 51: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/51.jpg)
Film Insert Molding (FIM) – preformed film
Boundary conditions
additional process for production of film
additional investment
automation
smaller process window
cleanness (clean room conditions)
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 52: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/52.jpg)
TPO - film
very often surfaces like leather
multi layerbarrier for flowwith and without foamed backing
lay-up in the mold preheated
application for intirior covers automotive
limitation in regard of small radius (otherwise surface defects)
characteristics
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 53: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/53.jpg)
TPO - film
Interior cladding part with TPO-film Daimler Chrysler Vito
Quelle/Source: Fa. Müller, Wallau
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 54: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/54.jpg)
TPO - film
Quelle/Source: Fa. Müller, Wallau
Back Molding Technology
Interior cladding part with TPO-film Daimler Chrysler VitoFilm
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 55: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/55.jpg)
TPO - film
Different applications
Quelle/Source: Fa. Müller, Wallau
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 56: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/56.jpg)
Backmolding of decorative wood
Quelle/Source: Fa. Summerer
Back Molding Technology
Film
FIM
Flat Film
PreformedFilm
TPO Film
Wood
IMD
![Page 57: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/57.jpg)
Back Molding Technology
Contents
1. Introduction
2. Decoration processes - overview
3. Technology for decoration with films
4. Technology for decoration with textiles
5. Special processes for decoration5.1 Back Molding with foamed material5.2 Sequential injection molding5.3 Compression injection molding
6. In Mold Labeling (IML)
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 58: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/58.jpg)
Cutting of textile
Back Molding of textile
Gripper takes theprecutted textile
Hand over to the mould
Mold isclosed
Back Molding withplastic material Mold opens
Molded part with excesslength of textile is taken out
Precuttingof textile
Process: without In Mold Cutting (conventional process)
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 59: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/59.jpg)
Back Molding of textile – without In Mold Cutting
Precutting of textilefrom a coil
Precutting of textile
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 60: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/60.jpg)
Precutting of textile
6- axis robot with CO2 laser head
Quelle/Source: Fa. Robot Technolgy
Back Molding Technology
Back Molding of textile – without In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 61: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/61.jpg)
Cover for C-column with excess length of textile
Insert excess length of textile
Quelle/Source: Fa. Müller, Wallau
Back Molding Technology
Back Molding of textile – without In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 62: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/62.jpg)
Covers for columns VW T5
Back Molding Technology
Back Molding of textile – without In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 63: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/63.jpg)
HM 13000 2P / 7700
Laser cutting with ABB 6-axis robor
Central ABB 6-axis robotEdge wrapping device
Back Molding Technology
Back Molding of textile – without In Mold Cutting
Covers for columns VW T5
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 64: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/64.jpg)
Interior door panel VW
Quelle/Source: Fa. Müller, Wallau
Back Molding Technology
Back Molding of textile – without In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 65: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/65.jpg)
Gripper takes theprecutted textile
Hand over to the mold
Mold is opened
Textile cutting
Precuttingof textile
Part ready to assembleis taken out
Process: In Mold Cutting (IMC))
Back Molding Technology
Back Molding of textile
Mold isclosed
Back Molding withplastic material
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 66: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/66.jpg)
Production cell (UNIROB R15 with gripper)
Textile cutting with laser
Hand over of textile
HM 3500/1900 + 130 L
Mould with IMCmoretechnology
Parts ready to assemble
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 67: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/67.jpg)
Gripper takes theprecutted textile
Hand over to themold
Mold isclosed
Back Moldingwith plastic material
Cutting of textilein the mold
Mold is closed
Precutting oftextile
Injection of TPEsealing
Part ready to assembleis taken out
Back Molding Technology
Process: In Mold Cutting with more material technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 68: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/68.jpg)
Process
Back Molding Technology
Gripper takes theprecutted textile
Hand over to themold
Mold isclosed
Back Moldingwith plastic material
Cutting of textilein the mold
Mold is closed
Precutting oftextile
Injection of TPEsealing
Part ready to assembleis taken out
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 69: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/69.jpg)
Precutting with laser system
high flexibility
less waste
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 70: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/70.jpg)
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Process
Gripper takes theprecutted textile
Hand over to themold
Mold isclosed
Back Moldingwith plastic material
Cutting of textilein the mold
Mold is closed
Precutting oftextile
Injection of TPEsealing
Part ready to assembleis taken out
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 71: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/71.jpg)
Hand over of the precutted textile to the mold
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 72: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/72.jpg)
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Process
Gripper takes theprecutted textile
Hand over to themold
Mold isclosed
Back Moldingwith plastic material
Cutting of textilein the mold
Mold is closed
Precutting oftextile
Injection of TPEsealing
Part ready to assembleis taken out
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 73: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/73.jpg)
Integration of functions
sealing of TPE
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 74: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/74.jpg)
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Process
Gripper takes theprecutted textile
Hand over to themold
Mold isclosed
Back Moldingwith plastic material
Cutting of textilein the mold
Mold is closed
Precutting oftextile
Injection of TPEsealing
Part ready to assembleis taken out
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 75: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/75.jpg)
Demolding
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 76: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/76.jpg)
solution 1 solution 2
Production cell
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 77: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/77.jpg)
Additional functions with 6-axis robot
cutout
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 78: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/78.jpg)
System solution
Video:System solution
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 79: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/79.jpg)
System solutions with partners
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 80: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/80.jpg)
= advantages for the moulder
saving of space
safe process
profitable
In Mold Cutting
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 81: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/81.jpg)
Future
Using of monolayer
special optical effects
cost advantages
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 82: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/82.jpg)
Future
Cutting of edges in the mold
Laser technology for flexible cutting and additional operations
Back molding with foamed material
fully automation of the production
machine supplier is more and more responsible for the whole system
Back Molding Technology
Back Molding of textile – with In Mold Cutting
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 83: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/83.jpg)
Back Molding Technology
Contents
1. Introduction
2. Decoration processes - overview
3. Technology for decoration with films
4. Technology for decoration with textiles
5. Special processes for decoration5.1 Back Molding with foamed material5.2 Sequential injection molding5.3 Compression injection molding
6. In Mold Labeling (IML)
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 84: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/84.jpg)
Special process: Back molding with foamed material
Motivation:
Increasing of the free flowing of the plastic material
Reduction of wall thickness
Reduction of weight (at the same wall thickness)
Reduction of warpage
Reduction of costs
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 85: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/85.jpg)
Cross section of a part molded with structural foam material
Closed cell structure
compact surface
Back Molding Technology
Special process : Back molding with foamed material
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 86: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/86.jpg)
Process characteristics for chemical foaming
feeding of chemical blowing agent
nucleation process for gas bubble production
maximum foaming pressure less than10 bar
application for bigger wall thickness
processing without problems and that which can be retrofitted easily
Back Molding Technology
Special process: Back molding with foamed material
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 87: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/87.jpg)
Process characteristics with phys. foaming (MuCell ®-process)
generating of with with direct injection of gas (N2, CO2 )
higher foaming pressure and foaming level
suitable also for thinner wall thickness
additional equipment necessary
license fee necessary
Back Molding Technology
Special process: Back molding with foamed material
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 88: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/88.jpg)
Machine equipment for injection molding of foam :
shut off nozzleincreased injection speedclamping of injection pistonincreased platen or Battenfeld 2 platen-IMM
MuCell®-process requires in addition :
SCF-Systemspecial screw fans for heater bands (similar to PVC-equipment)gasinjectoradditional software
New : Equipment for MuCell™-process that which can be retrofitted !
Back Molding Technology
Special process: Back molding with foamed material
Introduction
Film
Textile
SpecialProcesses
IML
Overview
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Kavitдt
Special process: Sequential injection molding
FlieЯfront
Both nozzles are closed
one nozzle is openone nozzle is closed
both nozzles are opened
Back Molding Technology
cavity
Melt front
Introduction
Film
Textile
SpecialProcesses
IML
Overview
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Advantages:
shorter flow distance
less filling pressure
less warpage
textile gently
no welding lines
Disadvantages:
more complex mold technology (hot runner with shut off needles)
Back Molding Technology
Special process: Sequential injection molding
Introduction
Film
Textile
SpecialProcesses
IML
Overview
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Special process: injection compression molding
Quelle/Source: Georg Kaufmann
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
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Advantages:
less filling pressure
less warpage
textile gently
Disadvantage:
more complex mold technology (vertical flash face)
not for all geometry suitable
Back Molding Technology
Special process: injection compression molding
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 93: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/93.jpg)
Back Molding Technology
Contents
1. Introduction
2. Decoration processes - overview
3. Technology for decoration with films
4. Technology for decoration with textiles
5. Special processes for decoration5.1 Back Molding with foamed material5.2 Sequentiell injection molding5.3 Compression injection molding
6. In Mold Labeling (IML)
Introduction
Film
Textile
SpecialProcesses
IML
Overview
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In-Mold-Labeling (IML)
Process :
Insert of the labelBack MoldingDemolding
Alternative process:
Thermoforming and printing
Mainly used for packaging parts (Thin wall)
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
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In-Mold-Labeling (IML)
Label (Film)
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
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In-Mold-Labeling (IML)
Container 250 g
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 97: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/97.jpg)
In-Mold-Labeling (IML)
Container with film
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 98: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/98.jpg)
In-Mold-Labeling (IML)
Advantages:
flexible in changing of decoration, suitable for small numbers
advantages in regard of hygienic-requirements
very short cycle times
up to 16 cavities possible
automatic changing of decoration
full automatic stacker
Back Molding Technology
Introduction
Film
Textile
SpecialProcesses
IML
Overview
![Page 99: Decorated parts in one process stepbattenfeld.ru/fileadmin/templates/docs/technologies/back moulding... · Decorated parts in one process step. ... Completely decorated molding out](https://reader034.vdocuments.net/reader034/viewer/2022042619/5a6ffc397f8b9a98538b8dc1/html5/thumbnails/99.jpg)
Thank you for your attention
more information : http://www.battenfeld.ru