11th project Surface treatment of plastic moulded parts · Within the project „Surface treatment“, for now 20 years, future-orientated processes are looked at, by which the participating

Title: Surface treatment 11Start: January 2019Term: 2 yearsCosts: (basic) 5.400 € p.a.*

(extended) 7.000 € p.a.*

Invoices are issued in two instalments. The first instal-ment due on start of the project, the second one ispayable after one year. *Member companies of the supporting organisation ofthe Kunststoff-Institut Lüdenscheid will have to contribu--te ten percent less.

Lateral entry is possibleEven after project start a lateral entry is possible at anytime.

Project data

You have access to further information on the projectcontent and its course via our website or direct contact:

Dipl.-Ing. Dominik Malecha+49 (0) 23 51.10 [email protected]

Katharina Prammer, B. Eng.+49 (0) 23 51.10 [email protected]

Information

Kunststoff-Institut für die mittelständische Wirtschaft NRW GmbH

(K.I.M.W.)Karolinenstraße 8 | 58507 Lüdenscheid

Tel.: +49 (0) 23 51.10 64-191Fax: +49 (0) 23 51.10 64-190

|

Surface treatment of plastic moulded parts

Aim of the project is the development of profoundknowledge and characteristics of technologies,testing methods and coating systems to gaincompetitive advantages and finally lower costs.The participating companies will be put into the positionto be able to evaluate and implement the technologiessafely and to recognise trends early, to meet thedemands of the market.Besides the extensive project services, networkingbetween the project participants provides furtherbenefit.

Aim of the project

Practical tests on in-mould-coating of a 3D moul-ded part

Research and practical tests on easy to clean surfacesand surface treatments

Trend and technology reports of the leading tradefairs on every project meeting, such as IAA, CESand IFA

Two or three project meetings per year for up to twopersons per company (change of participants is alsopossible)

Free of charge participation for one or two persons percompany for three seminars on surface technologies(over the period of two years)

Access to the „expert system“ for process selectionof surface- and decorating techniques

Access to the database for surface technologies Access to manuals, reports, studies, examinations

and lectures created in earlier projects (protectedlogin-area)

Exchange of experiences between the projectparticipants

Lectures of external speakers on special issues Extended: basic offer plus 30h for company-

specific investigations (within the duration of theproject)

Project services

PUR | easy to clean | trends

11th project

Joint-Project

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Project documentation in german and english

Within the project „Surface treatment“, for now 20years, future-orientated processes are looked at, bywhich the participating companies stay technologicallyup to date.From January 2019 on, the Kunststoff Institut givesonce again the opportunity to take part in this success-ful project with recently 45 participating companies.In addition to the new project services, the projectmembers gain access to all project outcomes in formof manuals, reports, studies and presentations etc. ofthe former project terms since 1997.

Introduction

Content Surface treatment

Project focuses

In-mould-coatingThe technology of in-mould-coating with PUR- andPUA-systems has already been extensively worked onduring the prior project terms in the last 4 years.Thereby numerous 2D test specimens, made of variousthermoplast and PUR combinations, have been prod-uced and many different tests according the performa-nce of the coating have been performed.Besides that, anti-adhesive tool coatings for a betterdemoulding and the demoulding behaviour of variousstructures have been investigated.The focus of the new project will be the coating of a 3Dmoulded part. Therefore the existing injection mouldingtool will be modified, so that the KIMW demonstrator„Naviblende“(navigation unit panel) can be coated in-side the mould. Gaps, edge radii and intersections givethe opportunity for various tests on demoulding, flowproperties and the surface quality in critical areas.Active venting inside the PUR-cavity will ensure thattrapped air can stream out, so that surface can be pre-vented from defects. In addition further investigationsusing the 2D sample sheet with various structures andinterfering contours will be made, to determine opport-unities and the limits of possibilities.

On this occasion, laminating possibilities on varyingwall thicknesses and gaps within the coating layer willbe determined.

Example of the demonstrator „Naviblende“

Easy to clean (E2C) surfacesTouch-sensitive operating panels and high-gloss sur-faces are more in demand than ever in almost allbusiness sectors. The high-graded optic of thesecomponents is noticeably affected by fingerprints.The visibility of a surface contamination is hardlyavoidable, but a functional coating for an easy clea-ning can be taken into account.

The work focuses break down as follows: Research for the state-of-the-art and latest develop-

ments Organisation and production of sample sheets with

potential E2C-systems Examination of the sample sheets referring to their

E2C-effect in consideration of automotive specific-ations

For the investigation of the cleanability of surfacescurrent test standards will be reviewed regarding totheir usability. Within the project an easily performa-ble test for easy-to-clean surfaces will be developed.

Technology and trend researchSurface technologies are developing rapidly. Besidesnew designs, which are wanted, the manufacturingtechnologies need to be modified or developed for acost-effective production of the demanded products.Modern ink and machinery sytems, as well as the in-tegration and automatisation, offer new opportunitiesfor digital printing technology.As part of this project, technological developmentsin the field of surface technologies for plastics will befollowed and future-orientated process progresseswill be shown. Trend reports from various leadingtrade fairs will be shown as an inspiration for theproject participants for current or future products.

What is a joint project?In a joint project, the institute does comprehensive research

terest. This is close to practice, with a high amount of tech-nical know-how and is funded by the participants` contri-bution only.

Advantages of a joint study Cost sharing = low contributions per participant Participating companies save personnel and costs Technological market leadership Networking Interdisciplinary exchange of experience

Time and cost intensive investigations as well as the organisation are carried out exclusively by the institute. The involvement of company employees is, at minimum, reduced to the participation at the project meetings.

Secrecy

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Joint project "Surface treatment 11" 1© Kunststoff-Institut Lüdenscheid

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Surface treatment of plastic moulded parts 11

Project focusesPUR | easy to clean | trends

© Kunststoff-Institut Lüdenscheid

Trends

Joint project "Surface treatment 11" 03/2019

Audi A8 | IAA 2017

Range Rover Velar D240 | IAA 2017

DéLonghi coffee maker Maestrosa | IFA 2018

Siemens dryer avantgarde | IFA 2018

Toshiba pressure cooker | IFA 2018

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Aim of the project

Joint project "Surface treatment 11"

Development and exchange of profound knowledge and characteristics of the following technologies

in-mould-coating (LiW)

Easy to clean surfaces – testing systems and coatings

Reliably assessing and applying of the techniques developed during the project

Introduction and early recognition of market trends

Networking between the project participants

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Motivation for participation


in-mould-coating gives opportunities, that might be impracticable with conventional coating systems (e.g. partial high-gloss and matt structures, self-healing effect)

The technology is well suited for decorative elements

The process combination with fuctional films enlarges the range of application

In the age of touch-sensitive operating panels, high-gloss surfaces an carsharing, product surfaces have to be easy to clean

New and practicable test methods for easy to clean characteristics are in demand

the market is developing rapidly. Technology- and trendreports provide advantages.

Reasons for participation:

Quick and easy gaining of knowledge

Reduced personnel requirements and shared costs

Constructive exchange of experiences and networking with experienced project and externalpartners

Access to the results of projects to date from 20 years

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IN-MOULD-COATING

Work package


Specific competences of KIMW


in-mould-coating

Accessible equipment for in-mould-coating

PUR-injection mould for sample sheets as a basis for practical tests

Extensive analysis technology for inspection of the practical tests

Process-specific experience gained over 4 years

Easy to clean surfaces

Market overview / database for coating systems

Application centre for surface treatment for coating tests with all common technologies

Accredited laboratory; appropriate for development, validation and publication of new testing methods

furthermore

Extensive network for surface treatment

Interdisciplinary exchange between the specialist departments

Project performances of the last periods of project

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Accessible equipment for in-mould-coating


“in-mould-coating” means coating with polyurethane and polyurea coating systems during the injection moulding process

Schematic representation of the process steps

03/2019

KIMW sample sheet; carbon fibres with clear compound

1. Injection moulding

2. Changing to second cavity

3. Reaction injection moulding (RIM) of 2K-polyurethane system

4. Removal of final coated part

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Accessible equipment


equipment

03/2019

Structure of an injection mould; KIMW sample sheetSchöfer GmbH

Injection moulding machineEngel VC330H/120 CO)

Dosing systemHennecke Streamline

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Opportunities opened up by in-mould-coating


haptic | soft -> hard

transparency | transparent -> opaque

surfaces | structured -> smooth

colours | different colours -> effects

Self-healing effect

Integration

Decorative film, wood, textile, …

Functional films (Printed electronics, …)

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leather grain, etched

laser structures

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Latest sample sheets – serial parts


source: https://www.peugeotnigeria.com/showroom/3008/suv/

source: Hennecke GmbH

PUR-sample sheet with three coating thicknesses(0,2/0,6/1,0 mm)

PUR-sample sheet with functional film

Decor trim A-pillar,moulded

Demonstrator Fakuma 2016

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Project servicespreparation of mould and samples


in-mould-coating (3D-shape)

Reconstruction of the actual mould for mould injection of a 3d-shape(KIMW demonstrator „Naviblende“(navigation unit panel))with active venting inside the PUR-cavity

Objects of investigation of this shape are:gaps, edge raidii, material accumulation for test on demoulding, flow properties, surface quality in critical areas, venting

in-mould-coating (PUR-sample sheet)

Preparation of cavity inserts with structures and interferingcotours for further tests

Determination of laminating possibilities on varying wall thicknesses and gaps within the coating layer

03/2019

KIMW „Naviblende“(navigation unit panel)

source: Schöfer GmbH

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EASY TO CLEAN

Work package

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Possibilities for the production of easy to clean (E2C) surfaces


Coating-, treatment- and „additive-“ systems foreasy cleaning of surfaces

Particularly smooth surfaces

low, non-polar surface free energies

hydrophobic – water rolls off

oleophobic – oily substances roll off

scratch resistance

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Current test standards for easy to clean surfaces


Test standards

BMW PR 506„Fingerprinttest on surfaces of interior parts“

Daimler DBL 5399„soiling / cleansing on interior parts and materials“

KIMW 004„test of cleanability“

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Specification of soiling, cleansing, appraisal

Test piece 35mm x 75mm

Cleaning direction

Valuation area(cleaned surface)

Test medium

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Accessible equipment and testing technologies for production and evaluation of E2C


OT - test engineering

AOT robotic painting

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Project services


Easy to clean (E2C) surfaces

Research for suitable surfaces and coating systems

Organisation and production of sample sheets with potential E2C-systems

Examination of the sample sheets referring to their E2C-effect in consideration of automotive specifications and by application of theappropriate test standards

Development/advancement of an easily performable test for surfaces(following the Continental E2C specifications TST N 001 16.11-000) andother testing methods, if necessary

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TREND AND TECHNOLOGY REPORTS

Work package


Trend research

03/2019Joint project "Surface treatment 11"

Trend and technology reports of the leading trade fairs for surfacetechnologies

IAA, CES, IFA, PMS, InPrint, HMI, Fakuma, „K“, as well as different congresses

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FURTHER PROJECT SERVICES AND DETAILS


Additional project services


Two or three project meetings per year for up to two persons per company(change of participants is also possible)

Access to mauals, reports, studies, examinations and lectures created in earlier projects (protected login-area)

Free of charge paticipation for one or two persons per company for threeseminars on surface technologies (over the period of two years)

Access to the „expert system“ for process selection of surface- anddecorating techniques

Access to the database for surface technologies (selection of suppliers)

Constructive exchange of experiences and networking with experienced project partners

Lectures of external speakers on special issues

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Project information


Project dates

Project launch : January 2019

Project duration: 2 years

Project costs: 5.400 € p.a. (basic)

7.000 € p.a. (extended)**including 30h for project-related commissioning

Applicable documents

Project brochure

Terms and conditions

Contact person:Dipl.-Ing. Dominik MalechaPhone: +49(0)2351.1064-132E-Mail: [email protected]

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Reference list JP Surface Treatment 11

1. BCS Automotive Interface Solutions GmbH, Radolfzell

2. Behr-Hella Thermocontrol GmbH, Lippstadt

3. Berlac AG, CH-Sissach

4. Continental Automotive GmbH, Babenhausen

5. Covestro AG, Leverkusen

6. Daikin Chemical Europe GmbH, Düsseldorf

7. Dr. Schneider Kunststoffwerke GmbH,Kronach-Neuses

8. Engel Austria GmbH, A-Schwertberg

9. Gigaset Communications GmbH, Bocholt

10. GXC Coatings GmbH, Goslar

11. Hennecke GmbH, Sankt Augustin

12. HIB-Trim Part Solutions GmbH, Bruchsal

13. John McGavigan Ltd., UK-Glasgow

14. KraussMaffei Technologies GmbH, München


15. Kunststoff-Zentrum in Leipzig gGmbH, Leipzig

16. Leopold Kostal GmbH & Co. KG, Lüdenscheid

17. Linden GmbH & Co. KG, Lüdenscheid

18. Marquardt GmbH, Rietheim-Weilheim

19. Momentive Performance Materials, Leverkusen

20. Montblanc Simplo GmbH, Hamburg

21. Novem Car Interior Design GmbH, Vorbach

22. Panadur GmbH, Halberstadt

23. Peter-Lacke GmbH, Herford

24. Preh GmbH, Bad Neustadt a. d. Saale

25. Rühl Puromer GmbH, Friedrichsdorf

26. Valeo Klimasysteme GmbH, Bad Rodach

27. Votteler Lackfabrik GmbH & Co. KG,Korntal-Münchingen

28. WEIDPLAS GmbH, CH-Rapperswil

29. Witte Bitburg GmbH, Bitburg

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Kunststoff-Institut Lüdenscheid Dipl.-Ing. Dominik MalechaKarolinenstr. 8 +49 (0) 23 51.10 64-132D-58507 Lüdenscheid [email protected]

For any further information do not hesitate to contact us.

http://www.kunststoff-institut.de/

Kunststoff-Institut für die mittelständische Wirtschaft NRW GmbH (K.I.M.W.) | Karolinenstraße 8 | 58507 Lüdenscheid | www.kunststoff-institut.de

Kunststoff-Institut Lüdenscheid Mr. Stefan Euler Karolinenstr. 8 58507 Lüdenscheid

Telefax: +49 (0) 23 51.10 64-190 Mail: [email protected]

Registration for joint project: Surface treatment of plastic moulded parts 11

Herewith we confirm our binding participation in the joint projekt above.Project manager: Dipl.-Ing. Dominik Malecha Katharina Prammer, B.Eng.Projekt costs: Exercise price: 5.400 €/Year incl. optional hour pool: 7.000 €/Year run-time: 2 Years Project start: January 2019 Documents: AGB und project flyer Member companys of our "Trägergesellschaft des Kunststoff-Instituts Lüdenscheid" pay a by 10 % reduced contribution.

Exercise price *2 including optional hour pool (+30 hrs)

Our purchase order number _____________________

We hand in our purchase order number later

Send us the invoice without purchase order number Please hand in your purchase order number within two weeks from the date of this document.After the expiration of this deadline we have to send the invoice without these information.

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