Injection Moulding Asia Moulding
Redesigning LEDS with Aura
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erman chemical firm Bayer MaterialScience (BMS) has licensed its Aura infusion technology for improving UV protection of moulded/extruded PC parts to US-based Radco Infusion Technologies for worldwide use. Because UV light attacks PC at the surface, UV protection is most effective when concentrated there, but this is not possible with traditional compounding of additives. This limits UV absorber effectiveness in outdoor applications, such as lenses and covers for lighting fixtures. Aura can be used with any of BMS’s Makrolon transparent PC lighting grades, allowing for what the company says is a breakthrough for lighting manufacturers, since it helps overcome the issue of yellowing after extended UV exposure. The infusion of UV additives via Aura utilises the same process used to add custom colourants. In this new twist, finished plastic parts are immersed in a mostly aqueous solution containing UV additives. The parts are removed from the solution after a short period of
LED lenses are the target for the new Aura infusion process
time, rinsed with water to remove excess solution from the surface and then dried to produce a marketready product. This allows the use of heat-sensitive additives that break down at extrusion/moulding temperatures but remain viable at the lower temperatures associated with infusion technology. The first commercial application using Aura will be launched this year by a major lighting OEM for an outdoor-use product with an LED lens injection moulded of Makrolon LED2643 clear tint plastic.
circular systems, for easy tip replacement in the press. The patent pending design is said to produce faster cycles because of an additional temperature control at the gate. The firm’s iFlow manifold brazing is also used for higher flow balance. Automation firm CBW will run Melt-Cube in a 16cavity system producing a 5-6 cc PP medical syringe with IML to showcase an anti-piracy tag. The mould will be supplied by Tech Mold and machine by Milacron.
An eye on coinjection and new gating system
Automotive
Toray and GMD to pursue automotive work
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ot runner supplier Mold-Masters will showcase its new coinjection hot runner technology for medical, beverage and food applications at the NPE event in April. IRIS will be shown in a workcell producing HDPE closures in a 16-cavity mould. The system will also incorporate a secondary injection unit and servodriven-valve gate control. The cap will be moulded with a 3-6% EVOH barrier encased in its centre, without the need for a secondary operation. Swiss supplier IMD will provide testing equipment along with downstream IMDvista INOX line for cooling, sorting and packing of the parts. Other partners include Engel Machinery that will provide the machine and F&S Tool, the tooling. Mold-Masters will also launch its linear side gate system Melt-Cube, said to allow for 20% higher pitch density than
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apanese carbon fibrereinforced plastics (CFRP) supplier Toray Industries has entered into a technical partnership with UK-based Gordon Murray Design (GMD) to pursue further development of GMD’s iStream manufacturing system and explore further opportunities for Toray’s materials in the automotive sector. Toray recently commissioned GMD to build a prototype twoseater electric sports car, subsequently named the TEEWAVE AR.1 (Toray Eco Efficient WAVE Advanced Roadster 1). It utilises the firm’s CFRPs and has a light body weight of 846 kg, including the battery. Both companies will further cooperate to reduce weight and cut costs in automotive design. The iStream is a design process in the making for 15 years said to reduce a facility size by 20% and investments by 80%.
Lower weight bumpers with new resin
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apanese vehicle maker Mazda and Japan Polypropylene have developed a PP/rubber resin for vehicle parts that maintains the same rigidity as parts made with conventional materials but with a weight reduction of 20%, especially in bumpers. In bumper production, a reduced thickness allows for a shorter cooling period for moulding and by using computeraided engineering (CAE) technology, the fluidity of the resin can also be optimised. As a result, the moulding time, previously 60 seconds, has been halved to 30 seconds. Mazda blended two components found in polypropylene (PP) and rubber, that have different properties, and succeeded in distributing them in a double-layer structure in line with the required function for the surface and the inside of the base bumper material. Thus, the surface has improved paint film adhesion and the inner section retains high rigidity and impact absorption, with reduced thickness. Mazda plans to adopt the light bumpers in its CX-5 SUV as well as in other upcoming new models.
The new Mazda with lighter bumpers to be launched later this year
3 MARCH 2012
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