applying seals and gaskets within the injection molding ... · pdf fileapplying seals and...

APPLYING SEALS AND GASKETS WITHIN THE INJECTION MOLDING CYCLE

C.A.S.E. high-pressure technology

IN PARTNERSHIP WITH INDUSTRY

KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide

Whatever you aim to achieve in plastics or rubber

processing, KraussMaffei is your partner. We are

the only company with intensive expertise across

the three main engineering fields. And we have a

strong track record in integrating this expertise to

develop new processes and systems.

Ready for any challenge

Our Injection Molding Machinery Division

supplies machinery and systems from 35 to 4,000

tonnes for standard applications and for all

processing variants, together with fully automated

solutions. We have a strong customer base in all the

relevant industries worldwide.

Our Reaction Process Machinery Division supplies

machines and complete systems for processing

polyurethanes and other reactive materials.

Completing our product portfolio, Automotive

Component Systems supplies foam molds, cutters

and routers. Our customer base is wide, with a

focus on the automotive, construction and white

appliances industries.

Our Extrusion Technology Division supplies

machinery and systems for compounding, for pipe,

profile and sheet extrusion, physical foaming, and

the production of technical rubbers and inter-

mediates for tire production. Machinery from the

company’s range – from single extruders to

complete extrusion lines – is used in many

industries, including chemicals, pharmaceuticals,

automotive, construction, furniture and packaging.

People for Plastics

We are the “people for plastics”. We are your

partners from the first exploratory discussion,

through development to commissioning, servicing

and operating your system, and final disposal. At all

times, you are assured of outstanding competence

in planning and engineering, as well as reliable and

fast spare parts, service and support.

Adding value for customers

We put our expertise to work for your success.

With machine ranges engineered for modular-

ity, we can deliver application-specific solutions

based on our wide range of standard modules and

specially engineered solutions. This strategy offers

customers technical and cost advantages.

Close to customers around the world

As an international company, KraussMaffei has

a presence in all the major markets for the plastics

and rubber processing industries and employs

around 3,000 people worldwide. Our sales and

service network keeps us close to all our

customers around the world.

Electrical / ElectronicsLife SciencesConstructionWhite GoodsAutomotive

Electrical / Electronics Packaging

A unique way to combine the benefits of injection molding with high-pressure polyurethane technology. C.A.S.E. high-pressure technology for fully automated application of seals and gaskets

With KraussMaffei high-pressure PUR technology, gaskets and seals can be applied directly and automatic-ally by the FiPFG method (formed-in-place foam gasket) during the injection molding cycle. The polyurethane system is engineered to accurately mix and meter small quantities of high-pressure foam. The outcome is PUR metering that boosts productivity, especially because no special purging cycles are required. The parts can be processed immediately, without the need for large buffer stations.

FiPFG with C.A.S.E. is available both as a compact system solution and as a retrofit to existing KraussMaffei injection molding machines.

Metering unitsAccurate, reprodu-cible metering of small polyurethane volumes

Micro-volume mixing head Developed in-house to de -liver low volumes with high precision under constant process conditions

Integrated plasma installation Integration optional; for activating the part surface

Space-saving system solution For easy link-up to other peripherals

TRANSPARENT TECHNOLOGY

Meet the machine: Take a tour of a C.A.S.E. system solution

Compact injection molding machinesfeaturing two-platen technology can be upgraded to C.A.S.E.

Industrial robotCompact interface, long action radius, easy programming

DETAILED PRODUCT INFORMATION

Conditioning in small doses to high standards. Polyurethane processing the KraussMaffei way

To integrate polyurethane technology into the

injection molding cycle, it is essential that the

processes be precision controlled and system

availability is high. These are the great strengths

of the RimStar modular platform. RimStar

machines stand for highly stable and reliable

processing where it counts – during conditioning

and metering of the polyurethane components.

The RimStar Nano and Comet Twin machines

are ideal for use in C.A.S.E. applications. These

metering machines can operate as stand-alone

solutions or integrated into a manufacturing cell.

Full-scale monitoring of material conditioning

for absolutely constant processes

For reproducible processes, the highly reactive

polyurethane components must be kept in a stable

temperature and pressure environment. To this end,

the machines are fitted with volume flow meters,

pressure and temperature sensors to monitor all

important parameters. And to ensure a consistently

high standard, they also have high-pressure heat

exchangers, special high-pressure filters and

rheologically optimized lines between the various

machine components. All these measures create

consistent processing conditions and a mixing head

with a shot always at the ready.

High-precision metering and delivery of the

PUR components

The properties of the materials being processed

dictate the choice of piston or pump metering.

Both pistons and pumps offer guarantee response

and precision control, combined with optimized

energy consumption. As a rule, high-precision,

servo-driven gear pumps are used to meter the ISO

component. The poly can be metered with a piston,

tandem piston or servo pump drive. With all these

variants to choose from, the system can be config-

ured cost-effectively for single-part production or

continuous production – using one or more cavities,

with or without fillers.

Built-in investment protection – thanks to

outstanding versatility and high availability

Systems such as the RimStar Nano, which is capable

of metering at an adjustable rate between 0.2 and

20 g/s per component, are a rock-solid choice for

conditioning totally disparate volumes for different

applications. The operator makes the necessary

settings via the control system – easily and reliably.

In addition, the fact that all machine components

are easy to access, gives it the extra advantage of

high availability.

One metering unit is capable of metering all the

PUR for all kinds of parts made on a number of

injection molding machines. Thus, a metering

unit could take center place within a star-shaped

production cell which is fed parts from several

injection molding machines. This boosts system

productivity, gives you even more production

flexibility and ensures a faster return on your

capital investment.


Metering units such as the RimStar

Nano offer a more reliable process

and superior product quality. They

are highly precise and have excellent

up-time, whether configured as a

stand-alone solution or integrated

into the injection molding cycle.


The mixing head holds the key to high-spec poly-

urethane processing. KraussMaffei has decades of

experience in the development and manufacture of

mixing heads and is the world leader in this field

of high-pressure technology. All this expertise

flowed into the development of the small-volume

mixing head that has set new standards in meter-

ing accuracy.

These mixing heads are currently the only high-

pressure models in the world that are capable of

reproducibly delivering as little as 2.5 g/s PUR

under production conditions. Such small delivery

volumes are a milestone in the development of

high-pressure mixing heads.

The mixing-head design – shot after shot

without cleaning

High-pressure mixing heads are self-cleaning – they

contain a cleaning piston which executes a move-

ment during each cycle (see diagram). There is no

need to interrupt production to purge and clean the

heads. Comparable low-pressure systems must be

periodically cleaned. This makes them more diffi-

cult to integrate into the injection molding cycle. In

some cases, this is wholly uneconomical. The per-

formance delivered by high-pressure mixing heads

is far superior to that of 2C low-pressure systems.

And this performance is crucial if PUR processing

is to be linked up with injection molding processes.


Small volumes at high pressure – the small-volume mixing heads from KraussMaffei

Uniform mixing without residues thanks to high-pressure technology

How high-pressure mixing heads work

Circulating position

(before the shot)

Shot position Cleaning position

(after the shot)

Cleaning pistonIso

Control piston

Poly

The KraussMaffei MK 3.5/5 UL-2KVV-40 mixing head is specially designed for homogeneous blending and precision

metering of the PUR system – time after time.

Small metering volumes & precision

process control

The transfer mixing head works on the counterflow

injection principle. The mixing head itself has

internal connections for attaching pressure and

temperature sensors, as well as an integrated high-

pressure filter. Very small nozzles ensure that even

components flowing at 0.7g/s in a ratio of up to

100/35 can be mixed homogeneously. The result is

high metering accuracy and tiny delivery volumes

as low as 2.5 g/s mixed material. The mixing head

geometry was especially designed to handle such

small volumes. Particular attention was given

to ensuring that small delivery volumes undergo

ex tremely intensive mixing with maximum

turbulence in the mixing chamber. The outflow

tunnel has a calming section that converts the PUR

mixture into laminar flow as it emerges from the

mixing head and thus affords extremely precise

and reliable process control. The PUR is always

metered accurately and reproducibly within narrow

tolerances and there is no dripping.

Detailed product information



KraussMaffei robots – the best way to link the reaction process with injection molding

To get optimum productivity from a system

solution, you need to control every step of the

process. Our robots serve as a flexible link for

melding the various steps into one process

sequence. The C.A.S.E. system solution relies

predominantly on industrial robots.

Accurate, highly dynamic movements

you can rely on

The industrial robot (IR) has been rejigged to execute

the precise trajectories needed for C.A.S.E.

That is the only way achieve uniform PUR application

within narrow tolerances. Where there is enough floor

space, linear robots can also be used. Six-axis or

linear technology aside, safety is always the para-

mount consideration. On account of their range of

movements and speed, industrial robots generally

pose a higher collision risk. To avoid this risk, IR

robots operating with KraussMaffei standard pro-

gramming can be returned to the home (default) posi-

tion simply by pressing a key on the control panel.

The concept has been designed for intuitive operation

and the user interface has been simplified to enable

the operator or set-up technician to easily and unam-

biguously start and stop the process via the control

panel on the injection molding machine. This success-

00 PRELINE

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Detailed product information

fully protects your machinery and the operator

without the operator having an in-depth knowledge

of programming.

As flexible as your business – floor-mounted

robots from our IR series

One outstanding feature of floor-mounted industrial

robots is their large horizontal radius of action. This

extraordinary reach delivers another benefit in that

it becomes simpler to integrate complex peripherals

such as additional assembly or test stations. This

type of application makes full use of the huge

versatility of an industrial robot. Quick-change

gripper connections and freely programmable

contours provide extra scope for running all kinds of

applications and docking the robots and the polyure-

thane processing cell onto other injection molding

machines. The programmable safety features are rea-

dily expandable – you can always be sure of optimal

protection to meet your growing needs. As a result of

this approach, our injection molding machines can

always be effectively automated to produce all kinds

of parts, with or without gaskets.


Our C.A.S.E. technology delivers more of every-

thing – more productivity, more efficiency, more

cost benefits. Choosing the right system partner

quite simply gives you “more”.

More productivity

The FiPFG/C.A.S.E combination enables you to

use fast-reacting foam systems, and so shortens

your production cycles. The compact design of the

reaction machine, coupled with our space-saving

two-platen injection molding machines, boosts the

productivity per square meter of your shop floor.

And the hard-wearing, self-cleaning mixing head

extends system up-time and increases productivity

even more.

More efficiency

Seamless process data logging and documented

product quality ensure that batch quality remains

at consistently high levels. Consumption of PUR

components is kept to a minimum with the high-

precision mixing head and because there is no need

for purging. Furthermore, the modular engineering

of the whole system means that system modules

can be used alone or in other configurations. They

can be utilized to full capacity producing all kinds

of products and generating a fast return on your

investment. Buying the complete system from a

single partner who looks after every aspect of the

solution saves on project-execution time. It also

makes for effective communications by eliminating

unnecessary interfaces – all helping you to get your

products to market faster.

CUSTOMER BENEFITS AND APPLICATIONS

Technical and cost benefits dovetail perfectly in C.A.S.E. system solutions

Covers for electronics equipment

Covers for electronics equipment can be produced

with much lower logistics effort.

Car speakers

In cars, bass speakers and other units can be

effectively uncoupled from vibrations – much

faster and in consistently high quality

with FiPFG.

Customer benefits and applications

More cost benefits

The fact that downstream processes can start soon

after the seal has been applied sharply reduces your

logistics costs, and boosts value creation accord-

ingly. PUR consumption is lower because there is

no purging, and costly scrap is avoided.

With a C.A.S.E. system solution, you can also

easily integrate in-line quality control after each

process step – in conformity with single-piece

flow in the Toyota Production System (TPS). The

outcome is consistent parts quality with minimal

consumption of resources for their production, and

hence more profit for you.

Summing up your benefits:

∙ Higher output due to uninterrupted injection molding and shorter cycles

∙ Substantially lower logistics costs due to elimination of large buffers

∙ Online application of sealant beads in a single-piece flow method

∙ Higher margins due to lower material consumption and minimal waste

∙ Fast return on investment due to flexible use of system modules in other productionconfigurations to maximize capacity utilization

A system for C.A.S.E. needs barely 24 m² to process every step of the value-adding chain for producing

gasketed medium-sized parts.

Unser Ersatzteilservice und Technischer Kunden-

dienst ist weltweit vor Ort im Einsatz und deckt

alle Fragen rund um Maschinen und Anlagen ab:

Wo immer Sie auch aktiv sind, wir unterstützen

Sie kompetent und schnell.

Wir bieten Ihnen nicht nur erstklassige Maschi nen

und Anlagen, sondern auch exzellenten Service.

Unter Service verstehen wir viel mehr als nur

Ersatzteile zu liefern oder Hotlines bereitstellen:

Gemeinsam mit Ihnen suchen wir nach der

technisch und wirtschaftlich optimalen Lösung

für Ihre Produktionsaufgaben, testen neue

Anwendungs themen und entwickeln individuelle

Leistungspakete.

Durchgängiges Service-Konzept

Unser Service-Konzept reicht von der Projektierung

über die Montage und Inbetriebnahme, Durchfüh-

rung von Kundentrainings, Maßnahmen zur Siche-

rung und Steigerung der Produktionsverfügbarkeit,

Betreuung und Wartung bis zur Modernisierung

Ihrer Maschine oder Anlage. So gewährleisten wir

zuverlässige Unterstützung beim Betrieb und schnelle

Hilfe bei Problemen. Erfahrene, speziell geschulte

Kundendienstmitarbeiter helfen Ihnen bei der Feh-

lersuche am Telefon oder lösen das Problem direkt

bei Ihnen vor Ort. Hilfreich ist auch die Klärung

per Ferndiagnose über die KraussMaffei Steuerung

Ihrer Maschine oder Anlage. Alle wichtigen Ver-

schleißteile sind kurzfristig lieferbar. Für schnelle

Ersatzteillogistik erweitern wir unser Servicenetz

ständig. Sprechen Sie mit uns – wir beraten Sie

gerne und finden für Sie die bestmögliche Lösung.

Kundenversuche im Technikum

Im Geschäftsbereich Spritzgießtechnik betreiben wir

seit Jahren ein eigenes Technikum. Hier können Sie

Maschinen und Anlagen testen, Prozesse einstellen

und optimieren. Dabei erarbeiten wir gemeinsam

mit Ihnen, welche Verfahren, Maschinen und

Ausrüstungen für Ihre Aufgaben jeweils am besten

geeignet sind und welche Technik Ihr Produkti-

onsvorhaben optimal unterstützt. Unsere hoch

qualifizierten An wendungsingenieure stehen Ihnen

dabei mit Rat und Tat zur Seite.

Kundenseminare mit hohem Praxisanteil

In unserem Technikum oder weltweit vor Ort

führen wir für Sie Seminare durch. Als Grund-

und Fortbildungsseminare rund um Bedienung,

Prozesssteuerung und Wartung von KraussMaffei

Spritzgießanlagen und als Spezialseminare zu kun -

denspezifischen Themen. Da unsere Seminare immer

einen umfangreichen Praxisteil an KraussMaffei

Originalmaschinen beinhalten, tragen sie dazu bei,

Sie in der betrieblichen Praxis noch sicherer, erfah-

rener und erfolgreicher zu machen.

SERVICE WORLDWIDE

Service, support and spare parts – when you need them, where you need them

Rely on us for a fast and competent response to

all your service needs anywhere in the world.

Whatever you need – from troubleshooting and

training to spares or repairs – we’re on the job.

We’re dedicated to supplying service quality on a

par with the outstanding quality of our machines

and systems. We offer far more than spare parts

and hotlines. We’ll work with you to choose the

best and most cost-effective solution for your

operation. We’ll help you test new applications

and we’ll plan customized service packages.

All-round service

Our service offering is broad. We’ll configure your

system, install and commission it, train your staff,

plan measures to minimize your downtime risk and

maximize productivity, and carry out maintenance,

repairs and upgrades. You’ll find us fast, reliable

and competent. Our hotline is manned by highly-

trained and experienced service technicians.

If necessary, we’ll get a technician to you quickly.

Remote diagnosis, interfacing directly with your

machine’s control system, can be a practical

alternative. Spares for all important wear parts are

available at short notice. We’re continuously

expanding our service network to speed up spare

parts shipment. Talk to us about the right service

solution for your business.

Customer trials and prototyping in our test lab

The Injection Molding Division operates a

test lab fitted with the latest machinery and

equipment. We can run trials, produce prototype

parts and fine-tune processes on your behalf. We

can work with you to test and evaluate processes,

machines and equipment in order to identify the

best approach for a particular project. Our highly-

qualified application engineers are there to help you.

Training with high hands-on content

Courses are held in our lab and training centre,

or, optionally, on your premises. We offer

clearly-structured basic and advanced training in

operation, process control and maintenance for

KraussMaffei injection molding machinery. On

request, we’ll plan and hold special courses on

topics of your choice. All participants spend a high

proportion of their training working hands-on with

original KraussMaffei machines. A well-structured

training program produces skilled operators and

technicians, which will positively impact your

up-time and productivity.

How to contact usHow to contact us

You can contact our Service and Spare Parts

teams around the world via this hotline or by

post at these addresses:

Service Reaction Process MachineryService Reaction Process Machinery

KraussMaffei Technologies GmbHKraussMaffei Technologies GmbH

Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2

80997 Munich80997 Munich

GermanyGermany

Phone: +49 89 8899-3152Phone: +49 89 8899-3152

Fax: +49 89 8899-4024Fax: +49 89 8899-4024

Service Injection Molding MachineryService Injection Molding Machinery

KraussMaffei Technologies GmbHKraussMaffei Technologies GmbH

Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2

80997 Munich80997 Munich

GermanyGermany

Phone: +49 89 8899-0Phone: +49 89 8899-0

Fax: +49 89 8899-2206Fax: +49 89 8899-2206

Team EuropeTeam Europe

Service Team Injection Molding Machinery

Email: [email protected]

Spare Parts Team Injection Molding Machinery


Krauss-Maffei UK (RPM)


KraussMaffei Germany (RPM)


OOO BKM Berstorff KraussMaffei

Service company (RPM)


KraussMaffei Italy (RPM)


Team America / SpainTeam America / Spain





KraussMaffei Corporation Mexico (RPM)


KraussMaffei Brazil (RPM)


KraussMaffei Colombia (RPM)


KraussMaffei Brazil (RPM)


KraussMaffei Japan (RPM)


KraussMaffei Korea (RPM).


KraussMaffei Shanghai (RPM).


Team Asia / Near East Team Asia / Near East





At your serviceAt your service worldwide worldwide

KraussMaffei Technologies GmbH

Krauss-Maffei-Strasse 2 ··· 80997 MunichPhone +49 89 8899-0 ··· Fax +49 89 8899 - 2206www.kraussmaffei.com

KraussMaffei is a premium partner for the plastics and rubber processing

industries worldwide. KraussMaffei machines and systems are used wherever

plastics and rubber are converted into products. As a knowledge-driven

technology company, we build on many decades of experience and a strong

commitment to research and development.

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With KraussMaffei high-pressure PUR technology, gaskets and seals can be applied directly and auto-matically by the FiPFG method (formed-in-place foam gasket) during the injection molding cycle. Parts are ready for downstream process steps almost immediately. Seal application is exactly reproducible and the seals test with excellent re-silience. Logistics effort and costs can be up to 75% lower than in 2C low-pressure processes. With their innovative technology fusion, KraussMaffei C.A.S.E. solutions offer you a significant competi -tive advantage. And they can be retrofitted easily to already installed injection molding machines.

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