Structural Foam Production Line

Fiber Reinforced RTM Production Lines

(Resin Transfer Moulding) or RTM

Metering Machines For The Production of Fibre-Reinforced Structural Parts Using The HP-RTM Process

Due to growing demands for efficiency and eco-friendliness, the

interest in lightweight solutions for the automotive industry has been increasing over the years. The focus is on extremely lightweight high-performance fibre composite parts which have so far been

made mostly in closed moulds using the resin injection process

(Resin Transfer Moulding or RTM). Extremely long process times are involved in classical RTM methods due to the relatively low pressures and the great amount of manual work required. This can be a

particular constraint for serial applications with large volumes. machines can combine high-pressure technology

with the classical RTM process. Here has broken new ground in developing polyurethane processing technology.

Thanks to the high level of automation and specific cycle times,

the high-pressure RTM process (HP-RTM) offers major advantages

in terms of efficiency and product quality. Besides polyurethane,

the advanced machine system can also handle epoxy systems,

even in the standard configuration. This gives users greater freedom in product development as well as for subsequent serial applications.

Building on the sale of over machines in the first generation, developers, manufacturers and raw material suppliers have been able to significantly advance this process in many respects, leading to diverse serial applications. We are proud to be a

pioneer in this innovative production technology . This passion for practical lightweight solutions is an integral part of each and has led to the metering machine becoming the standard for

HP-RTM applications across the world: use HP-RTM applications for serial components and has produced around applications so far using this renowned machine system. The machine configuration of the is

now embedded with extensive experience and process expertise. Our customers benefit from a highly developed product

which has been precisely adapted to serial applications in HP-RTM

processes.

Metering machines for the production of transparent and highly resistant polyurethane coatings in decor applications

Field of application for the is the surface finishing of parts, for example by coating them with

transparent or coloured PU systems using the RIM process (Reaction Injection Moulding technology offers an

innovative concept for the production of parts with high-quality and functional surfaces in a remarkably efficient way. A thin polyurethane layer is used to provide the finish to thermoplastic support elements or those with shiny and distinctive surfaces. This allows users to achieve scratch-proof, resistant, and high-quality surface structures for decorative parts in the automotive and furniture industries or for countless other decor elements. Moreover, it can be brilliantly combined with other processing techniques. This is well illustrated by the advanced process development resulting from in the field of mechanical engineering technology. Here thermoplastic moulded parts are combined with decor films or veneer elements in the injec­tion moulding process. The transparent or coloured PUR system finish is applied in the same production cell. A specially developed interface supports the integration of the system with an existing injection moulding machine.

Technology And Equipment

Standard Configuration

Even in its standard configuration, the is equipped with top-quality components. For example, mass flow metering of the main components allows the formulation to be preselected independent of density and ensures highest metering precision. Viscosity variations no longer play a role as the continuously

recirculated main components are kept at a homogeneous

temperature of up to 100°C. The efficient heating configuration is

also impressive when it comes to servicing: the heating and metering cabins are joined together using quick-locking mechanisms which allow for easy dismantling at any time. All main components (such

as pumps) can be exchanged in less than 15 minutes. The standard configuration also includes a vacuum unit to prevent air inclusions when storing the components in the day tank. A feed pump

ensures uninterrupted supply to the main metering unit – in spite of the vacuum. All components are mounted on a mobile frame which can be lifted by crane, thus enabling quick relocation on the

production floor and flexible operation in the laboratory at any time. The flexibility of the new STREAMLINE MK2 means that additional features can be retrofitted. As part of, the modular machine concept enables simple integration

of all available equipment options at any time.

Additive components

It can be extended with up to two pressurized

additive components such as a release agent or additional catalyst. Very small amounts of non-stable additive components can be introduced into the respective mould during the injection process. When a shot is requested, the additive component is metered into the component flow just before reaching the mix head and is

homogenized by a static mixer. The control system ensures an exact metering of each shot from start to finish by continuously

requesting the required filling level and recording the volumetric metering amount. Moreover, the combination of tank stirrer and

recirculation mechanism prevents the additive component from settling in the tank during storage. The additive station is connected separately to the and can be assembled close to the mix head. This ensures flexible assembly on the one hand, and short flow paths for the additive components on the other.

Heating The Additive Components

Upon request, the tank of the additive component metering unit can be equipped with a heating sleeve. This enables active and variable heating of the additive component up to a maximum of 50°C.

During the active metering process, the functionality can increase the output rate of an additive component such as a catalyst according to a specified function. The curing time can, for example,

be homogenized along the entire flow path and configured for the

particular part. This minimizes any distortion of the part. The tank

stirrer and the specially developed recirculation mechanism ensure that the accelerator components remain stable during the storage

process. The additional container for the catalyst is separately attached to the STREAMLINE MK2 along with the release agent station and

can be positioned near to the mix head.

Tank Assemblies

The tanks for the main components are part of an efficient and user-friendly heating configuration. This includes an insulated heating

cabin which accommodates the work tank and is connected to the heated tank for the metering line via a quick-locking mechanism.

Recirculation fans are used to heat the cabin up to a maximum

component temperature of 100°C. The cabin can be easily separated from the metering line and opened for maintenance works. All

components are conveniently accessible for maximum ease of service. Comprehensive insulation of the entire cabin prevents thermal bridges.

heating configuration is particularly energy efficient due to its high-quality design and is part of which incorporates highly efficient plant components for high-pressure metering

machines.

Metering Line

The components are fed to the mix head by high-pressure and axial piston pumps to ensure precise mixing and metering results. In addition to precision metering, these pumps provide comparatively high flexibility in terms of output rate. The pump speed can be adjusted by frequency control and the stroke can also be varied.

As a result, the system provides an extremely broad output range and a variety of mixing ratios for different matrix systems. Three different sizes are available. The pumps have been specially developed and adjusted to the requirements of the reactive components. In addition, by using a special high-pressure piston pump (HT30evo series), it is also possible to meter abrasive pigment colours or filler components and to deliver these to the mix head. All metering varieties of the new are connected to the tanks of the main components using quick-locking mechanisms. This ensures that the metering line is connected to the efficient heating configuration and at the same time can be quickly separated for maintenance works.