Back Moulding Technology

Back Molding Technology
Decorated parts in one process step

Contents
1. Introduction
Introduction
2. Decoration processes - overview
Overview
3. Technology for decoration with films
Film
4. Technology for decoration with textiles
Textile
5. Special processes for decoration
Special 5.1 Back Molding with foamed material
Processes
5.2 Sequential injection molding
5.3 Compression injection molding
IML
6. In Mold Labeling (IML)

Contents
1. Introduction
Introduction
Overview
Film
Textile
Processes
IML

Motivation
Increasing of profitability by:

Introduction
Integrated functions
Overview
Saving of the following process steps, e.g.
printing
Film
painting
laminating
Textile
high level of automation
Special
Processes
IML
Contents
1. Introduction
Introduction
Overview
Film
Textile
Processes
IML

Back Moulding Technology
Goal and way of solution
Completely decorated molding out of the injection molding machine

Introduction
Overview
Film
Back Molding of preformed printed films
Textile
Back Molding of printed carrier films
Special
Processes In Mold Decoration (IMD)
IML Back Molding of wood veneer
Back Molding of textiles
In Mold Labelling (IML)

Decoration processes
Films:
Introduction
In Mold Decoration (IMD) using embossing films
Overview
Film Insert Molding (FIM) using flat or preformed films
Film TPO Films
Textile Textiles:
Special Trimming as a separate process outside the mold

Processes
In Mold Cutting (IMC) = textile cutting in the mold
IML
Wood:
Veneer
Contents
1. Introduction
Introduction
Overview
Film
Textile
Processes
IML

Technolgy for Decoration with film
1. In Mold Decoration - IMD

Film
2. Film Insert Molding - FIM
IMD
Flat film
FIM
Preformed film
Flat Film
TPO film
Preformed
Film 1. Backmolding of wood
TPO Film
Wood
In-Mold-Decoration (IMD)
Film Principle:
IMD Film feeding device transports decorated film in between two opened
halfs of the mould
FIM
Back Molding of the film
Flat Film
Decoration relieves from the carrier film and fixes on the molding
Preformed
Film
TPO Film
Wood
Film feeding device

Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
Quelle/Source: Fa. Kurz

IMD-Films:
Film
single decorative film endless decorative film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
/Vitalo/
Principle design of the embossing film

Film
IMD Direction of back molding
FIM Decorative layer
Flat Film Scratch resistant Transfer layer

layer
Preformed
Film
Separation layer
TPO Film
Carrier layer
Wood
Process variable
Film
normal construction construction for depth effect
IMD
Decorative layer Plastic Plastic Decorative layer

FIM
Flat Film
Preformed
Film
Visible site Visible site
TPO Film
Wood
Multiple designs and functions

Film
Metallic-pigments
IMD
Metallized areas
FIM Brushed areas
Colour changing with temperature
Flat Film
Hologram
Preformed
Film Special scratch resistant
TPO Film Shielding effect
Wood
Applications :
Film
Automotive
IMD
Telecommunication
FIM Household and electronic
Cosmetics (Packaging)
Flat Film
Hifi
Preformed
Film Leisure and sports
TPO Film
Wood
Application: Automotive
Film
Product code for cars
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood

Film
Cover
IMD
FIM
Flat Film
Preformed
Film
Decorative molding
TPO Film
Wood

Film
Cover for heater control
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
Application: Telecommunication
Film
Display for mobile phone
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
Application: Telecommunication
Film
Housing for mobile phones
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood

Application: household /electronic

Film
Household goods
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood


Film
Household goods
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood

Film
Electronic
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood


Film
Cover for loud speaker
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood

Application: Cosmetic
Film
Aesthetic packaging
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood

Mold technology and accessories

Film
2- and 4 - cavity molds possible
IMD
Direct gating with hotrunner
FIM Positioning with printed brands
Tolerances at the molded part up to 0,02 mm
Flat Film
Closed loop control between film feeding device and optical sensor
Preformed
Film Communication between film feeding device and IMM via interface
TPO Film
Wood
Advantage
Film
high automation level
IMD
flexible in design and fast changing of decorative surface
FIM no pre-treatment
no solvents
Flat Film
good adhesion on the substrate
Preformed
Film decorative surface is able to cover welding lines
TPO Film
Wood
Boundary conditions
Film
special moulds
IMD
heat resistance of the film must be higher than melt temperature
FIM minimal number of pieces and timing for the production of the film
depth of the decorated surface is limited
Flat Film
radius are limited
Preformed
Film cleaning of the parts might be necessary
TPO Film
Wood
Film Insert Molding (FIM)
Principle:
Film
more thicker and rigid film (painted or printed) is inserted in the mould
IMD
films are preformed or not and cutted
FIM
flat and 3 dimensional parts can be molded
Flat Film
film is part of the molded article
Preformed
Film
TPO Film
Wood
Film Insert Molding (FIM)
Main applications:
Film
automotive
IMD
telecommunication
FIM medical technology
white goods
Flat Film
...
Preformed
Film
TPO Film
Wood
Film Insert Molding (FIM) flat films
Application: production of a tray

Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
System technology
Film buffer double gripper
IMD
mold
FIM
Flat Film separation of films
Preformed
Film
TPO Film
Wood film magazin
hot stamping of the rim transport of finished parts

System solution for back molding of films

Film
Video:
IMD system solution
FIM
Flat Film
Preformed
Film
TPO Film
Wood
cover for washing machine

Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
Material: PMMA
Film Insert Molding (FIM) preformed films
printed preformed precutted Final part

Film film film film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood process steps

Film Insert Molding (FIM) preformed film
Decoration of the film

Film
silk screen printing
IMD
Off- set printing
FIM colouring of the film
vacuum coating
Flat Film
scratch proof coated
Preformed
Film PVD coated
TPO Film
Wood
Quelle/Source: Fa. Bayer

Preforming if the film

Film
mechanical
IMD
hydraulic
FIM thermoforming
preforming during back molding
Flat Film
high Pressure Forming (HPF)
Preformed
Film
TPO Film
Wood
High Pressure Forming

Cutting
Film
cutting with knife
IMD for single samples
steel rule cutting die

FIM
depends on geometry
for pilot plant production
Flat Film
cuttiing die
Preformed
for mass production
Film
TPO Film
Wood

Insert and setting

Film
insert
IMD manual
with robot
FIM
setting
cores in the mold
Flat Film
ejector systems
Preformed slide (clamp)
Film pins out site the cavity
vacuum
TPO Film
electrostatic loading
Wood
Requirements for robot

Film
high precision with servo axes
IMD
suitable gripper
FIM cross head gripper
turning double gripper
Flat Film assembling of charging element
Preformed
Film
TPO Film
Wood
Insert of preformed films triode

Film
IMD
FIM
Quelle/Source: Fa. HAUG
Flat Film
charging generator
Preformed
Film
double gripper with 3 triods
TPO Film
filmmagazin
Wood
Tranport of finished parts

Application: cover for heater controls

Film
IMD
FIM
film
Flat Film
Preformed
Film
TPO Film
Wood end product
Material: PC
Application: cover for a car

Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood Material: ABS + PC/ABS

Application: cover for a car

Film Preformed and cutted film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood Material: ABS + PC/ABS final part

Application: side protector trim

Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood

Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
production cell with HM 3500 / 2280 and KUKA KR 30

Film clean room conditions

KUKA KR30/3
IMD
FIM
Flat Film
Preformed
Film
end parts
TPO Film
precentering of film
Wood
remove final part

insert of film
Requirements for the film

Film
transparency
IMD
suitable for printing
FIM elasticity for preforming
load-bearing capacity for cutting process
Flat Film
heat resistance
Preformed
Film shrinkage behaviour
TPO Film high surface quality
Wood
Advantages
Film
fast changing of decorating
IMD
multiple possibilities for decorating
FIM 3-D geometry possible
no pre treatment
Flat Film
welding lines can be covered
Preformed
Film protected printing
TPO Film
Wood
Boundary conditions
Film
additional process for production of film
IMD
additional investment
FIM automation
smaller process window
Flat Film
cleanness (clean room conditions)
Preformed
Film
TPO Film
Wood
TPO - film
characteristics
Film
very often surfaces like leather
IMD
multi layer
barrier for flow
FIM
with and without foamed backing
Flat Film lay-up in the mold preheated
Preformed application for intirior covers automotive

Film
limitation in regard of small radius
TPO Film (otherwise surface defects)
Wood
TPO - film
Interior cladding part with TPO-film Daimler Chrysler Vito

Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
Quelle/Source: Fa. Mller, Wallau

TPO - film
Interior cladding part with TPO-film Daimler Chrysler Vito

Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood

TPO - film
Different applications
Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood

Backmolding of decorative wood
Film
IMD
FIM
Flat Film
Preformed
Film
TPO Film
Wood
Quelle/Source: Fa. Summerer

Contents
1. Introduction
Introduction
Overview
Film
Textile
Processes
IML

Back Molding of textile
Process: without In Mold Cutting (conventional process)

Introduction
Overview Precutting Gripper takes the Hand over to

of textile precutted textile the mould
Film
Textile Mold is Back Molding with

Mold opens
closed plastic material
Special
Processes
IML Molded part with excess

Cutting of textile
length of textile is taken out
Back Molding of textile without In Mold Cutting
Precutting of textile
Introduction
Overview
Film
Textile
from a coil
Special
Processes
IML
Introduction
Overview
Film
Textile
Special
Processes
IML
6- axis robot with CO2 laser head
Quelle/Source: Fa. Robot Technolgy

Cover for C-column with excess length of textile

Introduction
Overview
Insert excess length of textile
Film
Textile
Special
Processes
IML


Covers for columns VW T5
Introduction
Overview
Film
Textile
Special
Processes
IML
Covers for columns VW T5
Introduction Central ABB 6-axis robot

Edge wrapping device
Overview
Film
Textile
Special Laser cutting with ABB 6-axis robor

Processes
IML
HM 13000 2P / 7700
Interior door panel VW

Introduction
Overview
Film
Textile
Special
Processes
IML

Back Molding of textile
Process: In Mold Cutting (IMC))

Introduction
Overview Precutting Gripper takes the Hand over to

of textile precutted textile the mold
Film
Textile Mold is Back Molding with

Mold is opened
closed plastic material
Special
Processes
IML
Part ready to assemble
Textile cutting
is taken out
Back Molding of textile with In Mold Cutting
Production cell (UNIROB R15 with gripper)

Introduction
Overview
HM 3500/1900 + 130 L
Film
Hand over of textile

Textile
Mould with IMCmore
Special technology
Processes
IML
Textile cutting with laser
Parts ready to assemble

Process: In Mold Cutting with more material technology

Introduction
Precutting of Gripper takes the Hand over to the

Overview
textile precutted textile mold
Film
Textile
Mold is Back Molding Cutting of textile
closed with plastic material in the mold
Special
Processes
IML Injection of TPE Part ready to assemble

Mold is closed
sealing is taken out
Process
Introduction

Overview
Film
Textile
Special
Processes

Mold is closed
Precutting with laser system

Introduction
Overview
Film
Textile
Special
Processes
IML
high flexibility
less waste
Process
Introduction

Overview
Film
Textile
Special
Processes

Mold is closed
Hand over of the precutted textile to the mold

Introduction
Overview
Film
Textile
Special
Processes
IML
Process
Introduction

Overview
Film
Textile
Special
Processes

Mold is closed
Integration of functions
Introduction
Overview
Film
Textile
Special
Processes
IML
sealing of TPE
Process
Introduction

Overview
Film
Textile
Special
Processes

Mold is closed
Demolding
Introduction
Overview
Film
Textile
Special
Processes
IML
Production cell
Introduction
solution 1 solution 2
Overview
Film
Textile
Special
Processes
IML
Additional functions with 6-axis robot

Introduction
Overview
Film
Textile
Special
Processes cutout
IML
System solution
Introduction
Overview
Film
Video:
Textile
System solution
Special
Processes
IML
System solutions with partners

Introduction
Overview
Film
Textile
Special
Processes
IML
In Mold Cutting
Introduction
Overview = advantages for the moulder
Film
saving of space
Textile
safe process
Special
Processes profitable
IML
Future
Introduction
Using of monolayer
Overview
special optical effects
Film cost advantages
Textile
Special
Processes
IML
Future
Introduction
Cutting of edges in the mold
Overview
Laser technology for flexible cutting and additional operations
Film Back molding with foamed material
fully automation of the production
Textile
machine supplier is more and more responsible for the whole system
Special
Processes
IML
Contents
1. Introduction
Introduction
Overview
Film
Textile
Processes
IML

Special process: Back molding with foamed material
Motivation:
Introduction
Increasing of the free flowing of the plastic material
Overview
Reduction of wall thickness
Film Reduction of weight (at the same wall thickness)

Reduction of warpage
Textile
Reduction of costs
Special
Processes
IML
Special process : Back molding with foamed material
Cross section of a part molded with structural foam material

Introduction
Overview
Film
Textile
Special
Processes Closed cell structure
IML
compact surface
Process characteristics for chemical foaming

Introduction
feeding of chemical blowing agent
Overview
nucleation process for gas bubble production
Film maximum foaming pressure less than10 bar
application for bigger wall thickness
Textile
processing without problems and that which can be retrofitted easily
Special
Processes
IML
Process characteristics with phys. foaming (MuCell -process)

Introduction
generating of with with direct injection of gas (N2, CO2 )
Overview
higher foaming pressure and foaming level
Film suitable also for thinner wall thickness
additional equipment necessary
Textile
license fee necessary
Special
Processes
IML
Machine equipment for injection molding of foam :

Introduction
shut off nozzle
Overview increased injection speed
Film
clamping of injection piston
increased platen or Battenfeld 2 platen-IMM
Textile
MuCell-process requires in addition :
Special
Processes
SCF-System
IML
special screw
fans for heater bands (similar to PVC-equipment)
gasinjector
additional software
New : Equipment for MuCell-process that which can be retrofitted !

Special process: Sequential injection molding
Introduction
cavity
Kavitt Both nozzles are closed
Overview
Film
Textile
one nozzle is open
Special Melt front
Fliefront
one nozzle is closed
Processes
IML
both nozzles are opened

Special process: Sequential injection molding
Advantages:
Introduction
shorter flow distance
Overview
less filling pressure
Film less warpage
textile gently
Textile
no welding lines
Special
Processes
Disadvantages:
IML
more complex mold technology (hot runner with shut off needles)
Special process: injection compression molding
Introduction
Overview
Film
Textile
Special
Processes
IML
Quelle/Source: Georg Kaufmann

Special process: injection compression molding
Advantages:
Introduction
less filling pressure
Overview
less warpage
Film textile gently
Textile
Disadvantage:
Special
Processes more complex mold technology (vertical flash face)
IML not for all geometry suitable
Contents
1. Introduction
Introduction
Overview
Film
Textile
Processes
5.2 Sequentiell injection molding
IML

In-Mold-Labeling (IML)
Mainly used for packaging parts (Thin wall)

Introduction
Overview
Process :
Film
Insert of the label
Back Molding
Textile Demolding
Special
Processes
Alternative process:
IML
Thermoforming and printing
Label (Film)
Introduction
Overview
Film
Textile
Special
Processes
IML
Container 250 g
Introduction
Overview
Film
Textile
Special
Processes
IML
Container with film

Introduction
Overview
Film
Textile
Special
Processes
IML
Advantages:
Introduction
flexible in changing of decoration,
Overview suitable for small numbers
advantages in regard of hygienic-
Film
requirements
Textile very short cycle times
Special up to 16 cavities possible

Processes
automatic changing of decoration
IML
full automatic stacker
Thank you for your attention
more information : http://www.battenfeld.ru

Back Moulding Technology

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Back Moulding Technology

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Back Molding Technology

Decorated parts in one process step

6. In Mold Labeling (IML)

6. In Mold Labeling (IML)

Increasing of profitability by:

6. In Mold Labeling (IML)

Goal and way of solution

Completely decorated molding out of the injection molding machine

Back Molding of textiles

In Mold Labelling (IML)

Special Trimming as a separate process outside the mold

6. In Mold Labeling (IML)

Technolgy for Decoration with film

1. In Mold Decoration - IMD

Film feeding device

Quelle/Source: Fa. Kurz

Principle design of the embossing film

IMD Direction of back molding

FIM Decorative layer

Flat Film Scratch resistant Transfer layer

Decorative layer Plastic Plastic Decorative layer

Multiple designs and functions

Quelle/Source: Fa. Kurz

Quelle/Source: Fa. Kurz

Quelle/Source: Fa. Kurz

Application: household /electronic

Quelle/Source: Fa. Kurz

Application: household /electronic

Application: household /electronic

Quelle/Source: Fa. Kurz

Application: household /electronic

Quelle/Source: Fa. Kurz

Quelle/Source: Fa. Kurz

Mold technology and accessories

Film Insert Molding (FIM)

Film Insert Molding (FIM)

Film Insert Molding (FIM) flat films

Application: production of a tray

Film Insert Molding (FIM) flat films

Flat Film separation of films

Wood film magazin

hot stamping of the rim transport of finished parts

Film Insert Molding (FIM) flat films

System solution for back molding of films

Film Insert Molding (FIM) flat films

cover for washing machine

Film Insert Molding (FIM) preformed films

printed preformed precutted Final part

Wood process steps

Quelle/Source: Fa. Kurz

Film Insert Molding (FIM) preformed film

Decoration of the film

Quelle/Source: Fa. Bayer

Film Insert Molding (FIM) preformed film

Preforming if the film

Quelle/Source: Fa. Bayer

Film Insert Molding (FIM) preformed film

steel rule cutting die

Quelle/Source: Fa. Bayer

Film Insert Molding (FIM) preformed film

Insert and setting

Film Insert Molding (FIM) preformed film

Requirements for robot