KraussMaffei Corp., Reaction Process Machinery

There were new presses of all stripes aplenty at K 2010, but the “wow” factor was supplied by automated work cells and integrated manu-facturing systems performing multiple operations before, during, and after molding.

Smaller parts, a wider range of resins and reinforcements,and retrofittable molding equipment were among the news indirect-compounded long-fiber thermoplastics presented at a recent Plastics Technology conference. Extrusion and thermoforming are also new extensions of this process.

A color-metering system for PUR is said to eliminate the risk of color carryover.

Polyurethane equipment at K 2007 in Dusseldorf showed incremental advances in cost-effectiveness and ability to handle a wide range of applications.

Two new tandem piston metering machines are specially engineered to handle abrasive fillers used in PUR automotive components.

A new in-mold painting process for long-glass reinforced polyurethane composite parts for cars, trucks, buses, and agricultural machinery was recently introduced by Germany’s KraussMaffei (U.S. headquarters in Florence, Ky.). With this in-mold painting approach, developed to produce smooth surfaces with the company’s LFI (long fiber injection) process, a paint layer is sprayed directly on the surface of the open mold.

A new approach to scoring airbag opening flaps on the B-side of automotive instrument-panel skins is said to achieve high precision and reliability at significantly reduced cost and operating complexity.

At this year’s K show, look for the launch of fiberglass/polyurethane pultrusion into window frames, as well as several new high-efficiency mixing heads, MDI prepolymers for cast elastomers, and an energy-absorbing PUR foam for car bumpers. PUR pultruded windowsBayer MaterialScience will showcase polyurethane pultrusion technology, which recently has penetrated new applications.

Germany's Krauss-Maffei (U.S. headquarters in Florence, Ky.) has teamed up with German moldtexturing expert Galvanoform to develop a process that combines K-M's PUR Long-Fiber Injection (LFI) process with Galvanoform's in-mold graining (IMG) technology.

A new metering machine for fi lled PUR is designed with two pistons operating in tandem to feed abrasive fi llers, fl ame retardants, or reinforcing fi bers.

A mini-volume PUR mixing head boasts highly precise processing at very low throughput rates.

A new electric mold carrier is said to be extremely robust with low-maintenance and clean, energy-efficient operation.

Krauss-Maffei Corp., Florence, Ky., recently opened its Detroit Competence Center in Novi, Mich., intended to provide increased local support for polyurethane processors serving automotive and specialty markets.

Several advantages are claimed for a new high-pressure spray mixing head for production of sandwich parts.

Despite the small number of polyurethane and RIM exhibitors, you will find some interesting new materials and equipment technology.One highlight will be a novel aliphatic PUR cast elastomer technology said to enable production of highly transparent parts with unique property profiles.

High toughness, fast cure, and no styrene fumes are taking urethane composites beyond SRIM into pultrusion, filament winding, vacuum infusion, and spray-up.

The Reaction Process Machinery Div. of Krauss-Maffei in Germany and Florence, Ky., is expanding its product line to include molds for PUR products.

Whether it was molding thermoplastic and polyurethane foam into one part in one machine, continuously foaming insulation between a metal pipe and thermoplastic skin, or pouring rigid foam behind a thermoplastic skin to replace steel refrigerator doors, there were plenty of novelties in PUR machinery and material among the exhibits at the K 2004 show in Dusseldorf last October.

Already a familiar sight on European store shelves, the eye-catching appeal of "IML" is gaining traction among North American injection molders. The latest tooling and automation designs can handle the higher volumes needed here.

 New equipment at the K show will include several mixing heads for flexible foams and RIM, mixing/metering machines, a gas loading device for rigid integral-skin foaming, and a low-pressure potting unit for electrical components.New PUR materials include a new insulating foams for oil and gas pipelines, thermal encapsulation of car engines, and a steel/PUR composite for maritime and civil-engineering structures. New mixheads galoreKrauss-Maffei is unveiling new mixing heads for various PUR applications.

NPE will show higher outputs of practically everything, as advances in grooved feeds, servo drives, screw torque, mixing screws, dies, and downstream cooling, cutting, and handling make everything run faster.

Gearless extrusion, cryogenic profile calibration, wireless data communications, and automatic start-up of blown film lines are just a few of the new ways to raise efficiency and output that were highlighted at NPE.

Stress-free production of large car windows, in-mold painting, and an injection unit that applies pack and hold while accumulating the next shot were a few of the cutting-edge technologies on display.