PRODUCTS
Fiat Stilo meets ABS+PA for quality interior
Appearance is increasingly a factor in vehicle interiors as
well as exteriors. Gleaming, metallic exteriors grab attention, but interior
components also need to be extremely functional – e.g. clear instrument
panel layout. Car designers want materials offering plenty of design scope,
plus a combination of mechanical and thermal properties. Bayer AG’s thermoplastic
polymer blend Triax KU2-3050 is being used in the new Fiat Stilo for the ventilation
components and visors. The material is said to have high scratch and impact
resistance, useful features for interior door panelling, door handles, electric
window control housings and rear-view mirror fixings.
Additional characteristics are high resistance to stress cracking, suitability
for injection moulding thanks to good flow properties, good dimensional stability
and resistance to distortion. It offers good resistance to light and fading
and incorporates UV protection.
www.bayer-ag.de
The new Fiat Stilo’s visors and ventilation components are made from
the opaque thermoplastic polymer blend Triax KU2-3050. High scratch and impact
resistance are claimed for the material, which requires no additional finish
such as paint.
Flexibility in Fuel System Hose Applications
Dyneon has recently launched its THV X 815 G fluoropolymer.
The manufacturers claim that the polymer will be helpful to automotive parts
manufacturers in elastomeric fuel system barrier hose applications such as
small diameter fuel and vapour lines and larger diameter fuel-fill hoses. New
evaporative (hydrocarbon) emission regulations in the US have meant that more
stringent specifications have been set for hose constructions. The company
claims that the polymer has good chemical resistance to a wide variety of
fuels, very low permeation, flexibility and ability to be co-processed with
and bonded to a variety of elastomeric materials. The performance characteristics
of the polymer are said to enable fuel fill hoses to be made in longer lengths
without sacrificing durability or permeation resistance. This, says the company,
allows designers to use a more flexible hose that offers good crash performance
and is easily shaped to provide design latitude and accommodate installation
requirements. The material is bondable to itself and other substrates
(for multi-layer constructions) and can be co-processed with many hydrocarbon
elastomers. Additionally, in accordance with OEM material specifications,
it can be used in automotive applications and does not contain extractables
that can clog fuel systems.
The company, headquartered in Oakdale, Minn, part of the 3M group, has operations
or representation in more than 50 countries.
www.dyneon.com
ULTRA HOT RUNNER NOZZLES IN FOUR SIZES
Husky Injection Molding Systems has introduced its new Ultra
series of hot runners. The nozzles are based on the proven properties of the
existing Husky 750 series. Now in four sizes, Ultra 250, 500, 750 and 1000,
they are designed for shots of between 1 and 1,000 g. A particular feature
of the nozzles is the use of stainless steel alloys. Their geometric design
was optimised using finite element analysis software. The result is an excellent
and simple-to-use operating window that leaves minimal residues. In addition,
the nozzles are suitable for even highly exacting plastics such as PEEK, PBT
and PVC. All Ultra nozzles are constructed identically as regards tip mounting,
the incorporation of heating elements and thermocouples and the use of the
valve gate. There are eight gating options for the processing of standard
polymers and high-specification polymers, including those that are highly
abrasive. A steel tip retainer ensures that the nozzle is reliably sealed
when the gate is in use. The valve stems are incorporated into the Husky UltraGuide
design, ensuring excellent gate quality and component longevity, even when
the shut-off is vertical. The in-built heating elements and thermocouples
designed for long-term reliability can be replaced within the machine itself.
All four nozzles make use of UltraSeal sealing technology, which involves
a spring pressing the nozzle, whilst still cold, against the runner. An operating
window of + 100°C is achieved thanks to this prestressing. Husky offers
a three-year guarantee on this sealing design, which it claims cannot be matched
by industry competitors. There is also a three-year guarantee on all components,
including heating elements and thermocouples, as well as nozzle tips.
www.husky.ca
Acetal Copolymer in Fuel Limit Valves
Stant Manufacturing, Inc., overcame stress cracking caused by
biodiesel fuel in an automotive fuel limit and vent valve (FLVV) by switching
from acetal homopolymer to Hostaform acetal copolymer made by Ticona, the
technical polymers business of Celanese.The shift in material for the FLVV,
which is used in diesel-powered vehicles slated for sale in Europe, was made
without having to alter moulding or secondary operations. European biodiesel
fuels contain rape seed methyl ether (RSME), which makes them significantly
more acidic than standard diesel fuels and more reactive with acetal and other
polymers.
The FLVV controls how much fuel can be placed in a fuel tank and has two major
components: a flange and a valve body. The flange, which cam locks into an
opening in the gas tank, has a diameter of 157 mm and a maximum thickness
of 12 mm at its outer edge. It also has three openings. One of these accommodates
a control valve that directs fugitive vapours from the tank to a carbon canister.
The other two are sending and return ports for the fuel sender unit in the
tank. The valve body descends from the flange and controls fuel height with
a float-and-spring mechanism. The flange and tank valve are moulded separately
and joined by spin welding. Total part length is 113 mm from the top of the
flange to the end of the valve housing. The FLVV also contains a retainer
and slosh plate, both of which are moulded from Hostaform acetal copolymer.
This grade of Hostaform acetal copolymer offers improved chemical resistance
for sustained use with biodiesel fuel blends at temperatures as high as 100°C.
It also has about 40 percent better elongation at break compared to standard
acetal, so it has improved impact resistance. In addition to FLVVs, this grade
is a good choice for use in such applications as emission control and rollover
valves, fuel reservoirs and fuel sender units in diesel-powered autos and
light trucks.
www.ticona.com
www.stant.com
Deformation and joint lines under control
The 900 mm long side pocket combination for the interior panelling
of the front side doors of the Mercedes-Benz Vaneo meet exacting standards
in terms of freedom from distortion; the joint lines are positioned so that
they are hidden, and there is no streaking on the visible surface. The Austrian
automotive supplier HTP (High Tech Plastics AG) initially manufactures three
injection moulded components – the base, the bottle holder and the elongated
cover – which are then welded together. The material used for all three
components is an impact-resistant Magnum ABS from Dow, which is highly suitable
for colour addition by the automobile manufacturer. The tools were designed
using Moldflow software to eliminate any problems in the development phase.
www.htp.at
www.resinex.net
SATURN FINDS PERFECT FIT AND LOOK
Roof appliqués moulded from DuPont Rynite PET thermoplastic
polyester resin meet tight fit and finish specifications for the Saturn VUE
sports utility vehicle. The appliqués are long, curved exterior parts
attached to the vehicle’s metal space frame above doors and behind rear
side windows. In addition to providing an elegant, finished look, the appliqués
help channel away rainwater while providing a rigid, smooth sealing surface
for the doors’ weather stripping.Two of the key requirements for the
appliqués is consistent fit and a Class A finish. Using the material
can also deliver savings on finishing costs. While SMC (sheet moulding compound)
or metal parts would require extensive sanding or other finishing steps prior
to painting, Saturn’s appliqués require only minimal surface preparation.
The consistent fit requirement is met by the material’s combination of
dimensional stability, low coefficient of linear thermal expansion (CLTE)
and warp resistance. Saturn’s appliqués, which are horizontally
oriented and subject to high thermal load in sunlight, resist heat-related
expansion and warping.The polymer contains both glass fibre and mineral reinforcements,
which helps assure that door seals have a uniform, rigid surface to press
against as they seal out the elements from the auto’s interior.A.P. Plasman
Corporation, Windsor, Ontario, designed and built the moulds for the appliqués
and currently moulds and paints them. The company developed proprietary tooling
and control techniques to achieve a uniform, polymer-rich surface that is
crucial to production of a smooth Class A finish that matches other vehicle
panels when painted.
www.plastics.dupont.com
Roof appliqués on Saturn’s VUE sport utility vehicle meet requirements
for Class A finish, precision fit, easy assembly.
Rolls-Royce Phantom drives with Rieter-Comfort
The new Phantom to be displayed at this year’s Geneva Auto
Show combines the latest high-tech with traditional luxury and comfort. As
the acoustic integrator, Rieter Automotive Systems, Winterthur/Switzerland,
was one of the chosen suppliers that helped make this extraordinary automobile
possible. Each Phantom contains approximately 150 separate parts, which make
up the interior floor, engine compartment and underfloor systems from Rieter.
These play a major role in sound reduction and thermal protection, contributing
directly to the overall comfort concept of the Rolls-Royce.
Both the Rieter Automotive Systems sites at Sevelen/Switzerland and Rossdorf/Germany
bring “Comfort thanks to Rieter” into the new Rolls-Royce. Sevelen
developed the insulation elements for the engine compartment, the heat shields
and the underfloor systems. Rossdorf produced the elegant, high-quality carpets
in twelve different colours. The preformed carpets, integrated carpet modules
with visco-elastic polyurethane foam backing for high acoustic performance,
were installed for the first time in a Rolls-Royce instead of flat carpet
panels. This concept adds flexibility in the interior design and reduces the
installation complexity.
Rieter Automotive Systems is a global supplier of systems solutions in the
field of noise control and thermal management as well as interior trim for
the automotive industry. The company employs a workforce of some 8,000 worldwide
and generated sales of USD 1,2 billion (1,9 billion CHF) in 2001.
www.rieter.com
The preformed carpets, integrated carpet modules with visco-elastic polyurethane
foam backing for high acoustic performance, were installed for the first time
in a Rolls-Royce (Photo: Rieter)
Automated injection moulding machine with tandem configuration tool
A key feature of the Boy 55 injection moulding machine is that,
in contrast with the tiered version, the mould is opened and moulded parts
are removed from it on one level while moulded parts are cooling on another
separate level. The residual cooling time of the one mould is therefore used
for metering, removing the moulded part and filling the other mould. This,
the manufacturers claim, enables the productive capacity of an automated injection
moulding machine to be increased by up to 12%, by reducing the delays due
to long cooling times.
Shown in the picture is a BOY 55 A with a tandem configuration tool. Additional
advantages of the equipment, according to the company Dr. Boy GmbH & Co.
KG from Neustadt/Germany, are the optimum power utilisation of the twin-plate
mould closure unit, the ample distance between the spars and plates, the low
energy consumption and compact structure.
Materials that can be processed in the machine include thermoplastics, elastomers,
duroplastics, liquid, silicon, metallic and ceramic powders.
www.dr-boy.de
