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EcoPower COMBIMOULD Highly versatile multi-component injection molding
EcoPowerstands forthe WITTMANN BATTENFELDinjectionmolding machines with small tomedium clampingforcesizes(55to550t),featuringahighlyefficientservo-electricdrivesystemcombinedwith a compact servo-electricclamping unit andleaninjectionunits intheinternationalstandard sizesof70 to 5000.
Combimould stands forWITTMANN BATTENFELD's multi-component injectionmolding technology.lIn thisprocess,abasicpartisproducedinthefirstinjectionmoldingstation,thenplasticcomponents indifferentcolorsormadeofdifferentmaterialsareaddedinoneorseveralmoreinjectionmoling stations,allinonecyclicalsequence.nthisway,variousmaterialaributesarecombinedwitheach other to create a composite part of better quality interms of visualattractiveness andfunctionality. This materialcombinationtechnology canbeused to produce individualparts as wellasintegrated componentsjoined togetherby assembly injectionmolding.Depending onthepartsgeometryin each case,this requires different process variants(for details see page 4).
EcoPowerCombimould from55to300tstandsforthecombinationof EcoPowermachines withoneor several additional plasticizing/injection aggregatesin various configurations.
FortechnicaldetailsofstandardEcoPowermachinesseetheEcoPowerbrochure.
EcoPower Combimould Applications
》Back molding
Simplebackmolding of two orthreeplasticlayers onabasepart orcertainareasthereof isthemost frequentapplication.Examplesaredecorations or anti-wearprotectionlayers.
》Assembly injection molding
By targeted use of the differencesinattributes of the plasticmaterials combined witheachother,assembliescanbeproduced with individual movable or detachable parts.Examples are flexible toyfigures, chainlinks,switch rockers or spout closures with resealing caps.
》Hard-softcomposites
Animportant field of applicationfor assembly injectionmoldingissealinstallation.nthisprocess,sealing lipsmadeofsiliconeorthermoplasticelastomerscan bemolded directlyontohousingbodiesortechnical parts in a second injection molding step.
》Overmolding
"Overmolding" is a special form of hard-soft combination,wheresoft,skid-resistantsurfaces arecreated onhousingpartsorappliancehandleswithelastomer layers.
Sandwichinjectionmolding-co-injectiontechnology This process serves toproduce parts with a three-layer structure,consisting of two continuous outersurface layers andacore layer.Interms of processtechnology, this is achieved by consecutive injection of two materials through the same nozzle into a conventional mold. A foamed orreinforced core componentimproves the part's mechanical attributes.Costs can be reduced by using regrind and Cellmould foam technology.The surfacelayers consisting of high-grade materials provide the desired high-quality surface attributes.In the packaging industry,barrierlayers canbeincorporated in theparts.Reproducible,attractive marbling effects canbeachievedbyswitchingseveraltimesbetween two materials of different colors.Depending on the areaofapplicationandtherequirementstobemetby theproduction equipment,a sandwich adapterplate or a sandwich and interval nozzle is used.
COMBIMOULD PROCESSTECHNOLOGY Optimally coordinated solution
》Valvegateretractionprocess
Toaddflatcomponentswithoutpartstransfer
In valve gate technology,the second componentis addedwithoutpriormoldopeningandrotation.The different geometryrequired insidethecavity is producedbyahydraulicvalvegatewhich,whenretracted, providesthespaceforaddingthesecond component.
In spite of a longer cycle time due to serial productionsteps,thevalve gateprocess maybe ofinterest economicallyinmoldtechnologyforsmall numbers of units because of the lower cost of mold technology. In some cases,the compact mold design even allows the use of smaller machines. However, a possible use strongly depends onthedesignof themoldedpart and onflatgeometriesof the additions.
》Indexplateprocess For complexpart design
Inindexplatetechnology,therotationand transfer mechanism is an integral part of the mold.This processmustbe appliedif the second component is to be added on both sides of the part.To this end,the preformmustbetransferredtoastationtoreceivea modifiedshapeonbothsides.Thisiscarried outwith the help of anintermediate plate inside the mold,also known as index plate,by which the parts are lifted out ofstation1,turned and thenre-inserted intostation2. The drive systemfortheindexplateiseitherintegrated in themoldormaybeconnectedto themachinewith a servo-electric drive.Rotations of +1 180 degrees(2 stations),120 degrees(3 stations) or 90 degrees (4 stations) are possible.Theindex plate system offers the maximumpossibleflexibilityformoldedparts engineering.
》Transfer process
Forspecial cases and small seriesprojects
This process is used as an alternative to the index plate process where the molded part No. 1, due to its geometry,has aninsufficientcontactarea ontheindexplate forbeing transported bytheindexplatebetween the injectionmoldingstations.Othertypesofapplications are combinations of bulky inserts (such as screwdrivers or knife blades) with plastic components,ora low-cost production alternativefor small series.
CLAMPING UNIT Servo-electric speed and dynamism
》Ample spacefor complex molds
Generously dimensioned mold platens [1] and a clean toggle lever clamping system offer the optimal environment for all molds including all media connections. The ejector area and the environment of the platens offer easy access for machine setup and adjustment work.[2]
》Sensitive andprecise
In theEcoPowerclamping system,the tie-bars are exclusively used for force transmissionbetween theouterplatens.Themovingplaten travelsvirtuallyfree of friction across the linearbearings without coming into contact with the tie-bars.[3]
》Servo-electricdynamism
The moving platenismoved quickly and with high precisionbya self-locking 5-point toggle lever.[4]
The toggle lever is driven by a highly dynamic servomotor viaa rackand-pinion drive system. [5]
The synchronized mold height adjustment via 4 bronze bar nuts and a sun gear system is driven by a servo motor.In this way, an extremely accurate clamping forceregulation canbe achieved.[6]
》Servo-hydraulicancillarystrokes
To drive the ancillary strokes(ejector,nozzle strokes and core pulls),a hydraulic aggregatepoweredbyaservo-electricmotor ismounted on theinside of themachine frame.Being specially designed for high efficiency,it requires no cooling waterconnection.Themaintenance-friendly access is from the rear,behind the clamping unit.Servo-mechanical drivesforthe ancillarystrokesare availableas options.
INJECTION UNIT Precision from beginning to end
INJECTION UNIT The right combination for every application
Inadditiontothe(horizontal)aggregateincluded inseries production,EcoPowerCombimould machines can be fitted inV(vertical) and L(horizontal at the rear of the machine) configurations.Simultaneous, paralleloperationofallservo-electricinjectionunitsispossibleasstandard.Allprocessvariantscanbeset individually.
》Vconfiguration
Injection from above,alsointo the mold parting line
-Generously dimensioned adjustment range
-Slide device with linear guides
-Simplehorizontal adjustment
-Vaggregate completelyretractableto therearto provide an absolutelyfree mold space
Nozzleposition stroke measurement incl.display in the control system
》Lconfiguration
Injection from the non-operatorside,even into the mold parting line
-Slide device free on the rear of the fixed platen
-Injection unit supported on linear guides
-Large adjustment range
-Access to the nozzles and to the mold from the rearvialargeoperatorsafetygate
-Fixedplatenfreeforstandardlinearrobot
-Nozzle position stroke measurementincl.display in control system
DRIVETECHNOLOGY Efficient through servo motors
Fast-responding,precise,cost-efficient
Theuseofservo-electricdrivetechnologyforallmainmovements affecting thecycleoffersalargenumberofadvantagescomparedto conventionalhydraulicinjectionmoldingmachines:
） Energyeffciencythroughdirectdrivewithoutenergyconversionintohydroenergy
》 Energyeffciencythroughtheservo drives'highefficiencyrates
》 Digital control formaximum repeatability
合 Use of recoveredbraking energyviaKERSsystemforpowering ofheaterbands
》 Cycle flexibility thanks to possibilities with parallel movements
》 Low sound emission (<65 dBA)
The combinationofservomotorsanddriveunits(rack-and-piniondriveforthetoggleleverandspindle drivefortheinjectionstroke)canbe supplied atdifferentperformancelevelsfordifferentspeeds.
Basically,theEcoPowerdriveconceptofferstheadvantageofmodularityfordemand-oriented adjustmentof driveperformanceto theintended useineachcase.
Servo-hydraulicdrivefor ancillarystrokes
_{\mathfrak{D}} Integrated in the machine frame without additional space requirements _{rm{\tinycent}} Drive unit forhydrauliccorepulls _{\gg} Energy-efficient,maintenance-freenozzle contactwithhighpressure 》No cooling required for standard applications
UNILOG B8 Complex matters simplified
The Unilog B8machine control system is the WITTMANN BATTENFELDsolution to facilitate the operation of complex processes forhuman operators.Forthis purpose, theintegratedindustrial PChasbeen equipped with an enlarged intuitivetouchscreen operator terminal.Thevisualizationscreenistheinterfaceto the newWindows10 loT operating system,which offers extensive process controlfunctions.Next to the pivotable monitorscreen,a connected panel/handset ismounted on the machine's central console.
Unilog B8
Highlights
》Operating logic with a high degree of self-explanation, similarto moderncommunicationdevices
》2majoroperating principles
-Operating/movementfunctionsviatactilekeys Processfunctions on touch screen(access via RFID, key card or key ring)
_{\mathfrak{D}} Processvisualization via 21.5" touch screen display (full HD) pivoting laterally
》New screenfunctions
UniformlayoutforallWITTMANNappliances
Recognition of gestures(wiping and zooming by
finger movements)
Containerfunction-split screen for sub-functions
and programs
》Statusvisualization
uniform signaling system across the entire WITTMANN Group
Headline on thescreenwithcoloredstatusbars and pop-upmenus
ambiLEDdisplayonmachine
》Operatorassistance
QuickSetup:processparametersetting assistant using anintegratedmaterial database anda simple query system to retrievemolded part data with machine settings pre-selection Extensivehelplibraryintegrated
COMBINATION OPTIONS EcoPower Combimould
| EcoPowerCombimould55 | |||
| Injection unit | 70H | 130H | 350H |
| 70 | V-L | V-L | V-L |
| 130 | V-L | V-L | V-L |
| EcoPowerCombimould90/110 | |||
| Injection unit | 130H | 350H | 750H |
| 70 | V-L | V-L | V-L |
| 130 | V-L | V-L | V-L |
| 350 | V-L | V-L | V-L |
| EcoPowerCombimould160/180 | |||
| Injection unit | 350H | 750H | 1330H |
| 70 | V-L | V-L | V-L |
| 130 350 | V-L | V-L | V-L |
| V-L | V-L | V-L | |
| EcoPowerCombimould240 | |||
| Injectionunit 70 | 350H | 750H | 1330H |
| 130 | V-L | V-L | V-L |
| 350 | V-L | V-L | V-L |
| V-L | V-L | V-L | |
| EcoPowerCombimould300 | |||
| Injection unit | 750H | 1330H | 2100H |
| 70 | V-L | V-L | V-L |
| 130 | V-L | V-L | V-L |
| 350 | V-L | V-L | V-L |
DATAEcoPower Combimould55-300
| EcoPowerCombimould55 | EcoPower Combimould 90/110 | EcoPowerCombimould160/180 | ||||
| Injection unit H | 70 130 | 350 130 | 350 | 750 350 | 750 1330 | |
| Weight!) | kg | 5000 5000 | 5200 | 6400 6600 | 7000 | 8600 9000 10600 |
| L | mm | 4000 4100 | 4400 4400 | 4700 | 5400 5600 | 5900 6600 |
| W | mm | 1400 | 1500 | 1600 | ||
| H | mm | 2000 | 2100 | 2200 | ||
| Injection unit V | 70 | 130 70 | 130 | 350 70 | 130 350 | |
| HV | mm | 3500 3700 | 3600 | 3800 4100 | 3800 4000 | 4300 |
| EV | mm | 170 | 170 | 220 | ||
| DV | mm | 60 | 60 | 60 | ||
| W | mm | 90 | 90 | 115 | ||
| SV | mm | 75 | 100 | 125 | ||
| 350 | ||||||
| Injection unit L | 70 | 130 70 | 130 | 350 70 | 130 | |
| BL | mm | 2300 | 2300 2300 | 2300 | 2500 2300 | 2300 2500 |
| EL | mm | 195 | 195 | 245 | ||
| DL | mm | 60 | 60 | 60 | ||
| VL | mm | 90 | 90 | 115 | ||
| SL | mm | 75 | 100 | 125 | ||
| EcoPower Combimould 240 | EcoPower Combimould 300 | ||||||
| 350 | 750 | 1330 | 750 | 1330 | 2100 | Injection unit H | |
| 10900 | 11300 | 12900 | 14100 | 15700 | 17900 | kg | Weight!) |
| 6400 | 6400 | 7100 | 7000 | 7700 | 8300 | mm | L |
| 1800 | 1900 | mm | W | ||||
| 2400 | 2400 | mm | H | ||||
| 70 | 130 | 350 | 70 | 130 | 350 | Injection unit V | |
| 3900 | 4100 | 4400 | 4100 | 4300 | 4600 | mm | HV |
| 245 | 295 | mm | EV | ||||
| 75 | 75 | mm | DV | ||||
| 150 | 150 | mm | W | ||||
| 125 | 125 | mm | SV | ||||
| 70 | 130 | 350 | 70 | 130 | 350 | Injection unit L | |
| 2300 | 2300 | 2500 | 2300 | 2300 | 2500 | mm | BL |
| 270 | 325 | mm | EL | ||||
| 75 | 75 | mm | DL | ||||
| 150 | 150 | mm | VL | ||||
| 125 | 125 | mm | SL | ||||
| 70 | |||||
| Screwdiameter | mm | 14 18 22 | |||
| Screw stroke | mm | 70 90 90 | |||
| Screw L/D ratio | mm | 20 | |||
| Theoretical shot volume | cm3 | 10.8 22.9 34.2 | |||
| Specific injection pressure | bar | 3000 2593 1736 | |||
| Max.screw speed | min"1 | 600 | |||
| Max. plasticizing rate (PS)2) | g/s | 2.0 6.0 8.6 | |||
| Screwtorque | Nm | 65 120 150 | |||
| Nozzle stroke/contact press | mm/kN | 250/40 | |||
| Injection rate into air | cm3/s | 61.6 102.0 152.0 | |||
| Barrel heating power | kW | 2.9 5.5 6.3 4 | |||
| Number of heating zones | |||||
| 130 | |||||
| Screw diameter | mm | 18 22 | 25 | 30 | |
| Screw stroke | mm | 90 110 | 125 | 125 | |
| Screw L/D ratio | mm | 20 20 | 22 | 22 | |
| Theoretical shot volume | cm3 | 22.9 41.8 | 61.4 | 88.4 | |
| Specific injection pressure | bar | 3000 2864 | 2218 | 1540 | |
| Max. screw speed | min"1 | 500 500 | 400 | 400 | |
| Max. plasticizing rate (PS)2) | g/s | 5.0 7.2 | 10.5 | 15.4 250 | |
| Screw torque | Nm | 120 150 250 | |||
| Nozzle stroke/contact press | mm/kN | 250/40 | |||
| Injection rate into air | cm3/s | 50.9 76.0 98.2 141.0 | |||
| Barrel heating power | kW | 5.5 6.3 9.0 10.4 4 | |||
| Number of heating zones | |||||
| 350 | |||||
| Screwdiameter | mm | 30 35 40 | |||
| Screw stroke | mm | 150 175 175 | |||
| Screw L/D ratio | mm | 22 | |||
| Theoretical shot volume | cm3 | 106 169 220 | |||
| Specific injection pressure | bar | 2835 2083 1595 | |||
| Max. screw speed | min'1 | 350 | |||
| Max. plasticizing rate (PS)2) | g/s | 13.5 21.0 33.5 | |||
| Screwtorque | Nm | 500 | |||
| Nozzle stroke/contact press | mm/kN | 250/40 | |||
| Injection rate into air | cm3/s | 141 192 251 | |||
| Barrel heating power | kW | 10.4 10.4 12.9 | |||
| Number of heating zones | 4 | ||||
Due to the great variety of TPE types,the bonding strengthmustbe checked in each individual case.
The bonding strength also depends on the part geometry, process conditions and processes involved.
Bonding of thermoplasticmaterialsinmulti-componentinjectionmolding
| TPE based on polyamide | TPE-polyester- elastomers | TPE based on polyolefin | TPE based on styrene | TPEthermoplas- ticplyurethane | TPE types with modified adhesi- veproperties | |
| ABS | ■ | 口 | ■ | ■ | ||
| ASA | ||||||
| CA | ||||||
| PA 6 | # | ■ | ■ | # | ||
| PA 6.6 | ■ | |||||
| PA-Blend | # | 口 | 口 | # | ||
| PBTP | ■ | 口 | ■ | # | ||
| PC | ■ | 口 | ■ | 口 | # | |
| PC/ABS | ■ | 口 | ■ | 口 | # | |
| PC/PBT | ■ | 口 | ■ | 口 | ||
| PC/PET | ■ | 口 | ■ | 口 | ||
| PE | ■ | 口 | 口 | |||
| PETP | ■ | |||||
| PMMA | 口 | 口 | ||||
| POM | ■ | |||||
| PP | ■ | ■ | # | |||
| PPO | ■ | |||||
| PS | ■ | ■ | ■ | # | ||
| PAN | ■ |
WITTMANNBATTENFELDGmbH WienerNeustadterStrasse81 2542 Kottingbrunn|Austria Tel.: +43 2252 404-0 info@wittmann-group.com www.wittmann-group.com
