Tetra Project

Variotherm in combination with Large

Structural Foam Injected Product

IMPROVING (Y)OUR BUSINESS

Agenda :
- Bedrijf Neaforma

- Wat is Structural Foam Injection (SFI)

- Techniek
- voor- en nadelen

- Variotherm
- Matrijsconcept
- Keuze van temperier
- resultaten
 Company Profile
WHO we are for WHO
1971 : Foundation of company by Guy Taillieu
Synonym for Plastic Solutions Ventilation (HVAC)
to improve your business
Production facilities :
1977 : Orac Decor
• Belgium (Ostend) - headquarters Medical
• Slovakia (Lipany) 1987 : Orac Industries Machinery
Moulded Plastic Parts
Spin-off of Orac NV 1998 : Structural Foam Injection Building

1999 : Orac Slovakia

2000 : Structural Foam Extrusion

WHAT2005 : Implementation of SAP

HOW
we make
2007 : New Offices we work
Foamed Plastic Products
Our One...
2008 - 2010 : Technologies : insulation, EMI-shielding, Stop
. Shop approach
Which give an alternative to traditional materials
Technologies is the base for a long term relationship
•Strucutral Foam Injection with industrial partners
2011 : NEAFORMA and ISO 14001
•High Pressure Injection
•PUR/RIM SAP/ERP system
Wide variety raw material
2012 : NEW ENGEL DUO 1700
Small – Medium sized quantities (500 –
Quality assurance
ISO 14001
50.000)
 Company Profile : Facilities
WHO we are
Synonym for Plastic Solutions - Head Office
to improve your business - Injection and extrusion
Production facilities :
- 15,000 m2 site
• Belgium (Ostend) - headquarters
(50,000 m2)
• Slovakia (Lipany)
Moulded Plastic Parts
Spin-off of Orac NV Belgium

Slovakia

- Belgian manager
- Production of polyurethane
products + varnish
- 10,000 m2 site with buildings
(50,000 m2)
- Subcontracting
 Company Profile : Market Range
WHO we are for WHO
Synonym for Plastic Solutions Ventilation (HVAC)
to improve your business
Production facilities :
• Belgium (Ostend) - headquarters Medical
• Slovakia (Lipany) Machinery
Moulded Plastic Parts
Spin-off of Orac NV Building

WHAT HOW
we make Product cost we work
Foamed Plastic Products Our One Stop Shop approach
Which give an alternative to traditional materials is the base for a long term relationship
Technologies with industrial partners
•Strucutral Foam Injection
•High Pressure Injection
•PUR/RIM SAP/ERP system
Wide variety raw material Quality assurance
Small – Medium sized quantities (500 – ISO 14001
50.000)
Technologies : Structural Foam Injection
 Structural Foam Injection : Advantages
MAIN ADVANTAGES :
- Excellent 3D stability (no ribs needed)
- No or low warpage (no internal stresses)
- Varying wall thicknesses (1mm - 4mm – 12mm …)

10

3
25

FURTHER ADVANTAGES :
- Constructif : structural strength
- Viscosity reduction due to blowing agent (easier flow)
- Density reduction (weight reduction) : ±10%
- Noise reduction (ventilation)
- Inserts possible
- Solution to avoid “Sink-marks”
- Recycable
- Water-resistant : hard and closed skin
- EMI-shielding (medical)
 Advantages : Economic Advantages

aterial : Density reduction

ould : Aluminium mould

achine : Low pressure injection

ycle times : Wall thickness starting from 3 to 4mm

 Advantages : Density Reduction
Density in relation to Wall thickness
1100
Compact (high pressure injection)
HIPS/ABS
1000
D
e 900 Structural Foam Injection :
n Visual acceptable area
s Density : ± 0,85 – 0,9 kg/l
i 800
t
y 700
(

k 600
g HIPS/ABS
/
m 500
ABS
³
“LD” Structural Foam Injection :
)

400
Visual acceptable area HIPS
Density : ± 0,45 – 0,55 kg/l
300
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Wall thickness (mm)
 Advantages : Cooling Cycle
Cooling time in relation to Wall thickness
HIPS
600

C
o 500
o 475
l
i
400 high - 52% : Structural Foam Injection
n pressure
g injection HIPS
HIPS
300
t
i
225
m
e 200
150
(

s - 68% : “LD” Structural Foam Injection

100
e
70
c
- 43% : Structural Foam Injection
)

40
0
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Wall thickness (mm)
Disadvantage : Swirl Effect
 Variotherm : Project Variotherm
Project for company BARCO: R725013
R725015

Raw Material : HIPS V0

Tg = 96,14°C R725014
(defined by KULeuven)
Wall thickness = 4mm

Reference Cycle Time Cavity Injection Weight Weight

(cycle+variotherm) mold Insert
R725013 50+30 sec. 2 Tunnel 1,5 ton 2 x 30 kg
R725014 60+45 sec. 1 Cone 2,5 ton 240 kg
R725015 70+60 sec. 1 Cone 8 ton 500 kg

Calculation kW temperier :
40 sec cooling time (70 sec cycle time)
130 – 40 = 90 sec to heat up insert VARIOTHERM
 Variotherm : temperier
Overview - Common heating technologies
Water Induction Infrared Ceramic Steam

Approved technology
Suitable for large parts
Low extra costs for production equipment
Maximum cavity temperature: ~ 180°C
Variotherm : temperier
Variotherm : temperier
Variotherm : temperier
 Variotherm : temperier

OFFERS :

GWK :
- 72 kW
- 120 kW (€ 120.000)

SINGLE :
- 72 kW op 150 en 180°C (€ 57.000 – € 63.000)
- 48 kW op 150 en 180°C (€ 47.000 – € 53.000)

HB term :
- out of range (geen aanbieding)
 Variotherm : mould design
Variotherm Insert R725014: Weight reduction
+ insulation

Cooling channels :
G1 D = ø12

2D

1,5D

G1
 Variotherm : temperier
Variotherm Insert R725014:
Evolution : cooldown
Variotherm : huur temperier
R725013: Variotherm

Textured
mold

Polished
mold
R725014: Variotherm
Front Back

Without
Variotherm

With
Variotherm
R725014: Variotherm : Leppard skin
Mold Mold - Product
 Variotherm : Leppard skin
Future Actions
 Variotherm

Conclusions of the first tests :

- Variotherm gives good results !

- Temperier : Kw too low for testing => higher cycle time
- Cooling circuits must be modified
- Further investigation on the Leppard Skin

- New technology :
- Thin film heating (Fraunhofer)
Cupper layer with very thin thermocopples builded in
Ceramic protective layer on top (10µm)