Overview 2015 Innovative Molding Technology
- Creation of the Company: 2000 - Technology Provider for Plastic Injection and Compression - Most advanced Heat and Cool technology in the industry - Engineering Team 100% focused on Heat & Cool solutions - R&D investment since its creation: $1.1M/Year ($22.5M total) - Facilities in Europe, Asia and North America
RocTool Offices France Taiwan USA Japan Italy Germany Headquarters & Demo Center Office & Demo Center RocTool Inc. Office & Demo Centers Office & Demo Center Demo Center RocTool GmbH Office & Demo Center
Markets Aerospace Consumer Electronics Automotive Sport and Energy Cosmetics Products Leisure
3iTech Overview - High speed heating of the tool surface with integrated induction network - Cooling with water lines - Complete mold temperature control with easy interface (thermocouples) - Process designed for standard steels - Full automatic mode compatible with all press machines
3iTech Primary Technology Close up of the inductor cavity: Molding Surface Induced Currents Injected Currents Magnetic Fields Mold in Magnetic Steel - Example 1.2343 (H11) - Electric resistivity ρr:40 Ω.m - Relative permeability μr:55 - Thermal conductivity k:27w/m.k Thermal Diffusion Insulating Layers (1 or 2) Inductor (copper)
3iTech Design Configuration 1 Configuration 2 - Channels are accomplished by drilling or machining from Ø6 to Ø11mm Heating Channels Cooling Channels - Soft inductor in copper Configuration 3 Molding Surface - Conventional cooling channels from Ø6 to Ø12mm Configuration 4 Configuration 5-3D shape is possible 3iTech configuration
A complete process integration Patents and License Generator Engineering Tool Design Development & Packages and FEA Support Production Support Complete Induction Heat & Cool Package includes: - Engineering / Simulation & Full Analysis - Generator Package with Peripherals - License and know how transfer - Installation, Start Up & Complete Training
Performance & Combination Cage system 3iTech Heating Configuration Slightly Closed Fully Open/Close Stage Heating Control Before Press Closing At All Times (Possible Between Cycles) Power Input 50 to 500kW 15 to 500kW Process Combination 2 Side Heating Same T 1 Side + Silicon Core 1 Side + Vacuum 1 Side / 2 Side Heating 2 sides Different T Local Heating 1 Side + Silicon Core 1 Side + Vacuum Vacuum Moving Elements
Performance Benchmark Heating Speed Temperature Energy Cost Process Performance Induction Heating Up to 25 C/sec Up to 400 C Low to Medium Extended Flow Processes* (Steam; Pressurized water) Up to 10 C/sec Up to 140 C Medium High Limited Electric Heater* Up to 5 C/sec Up to 300 C Very High Limited MATERIAL AND DESIGN (2010) 382 395 Research of thermal response simulation and mold structure optimization for rapid heat cycle molding processes, respectively, with steam heating and electric heating - Guilong Wang, Guoqun Zhao, Huiping Li, Yanjin Guan
RocTool Engineering An Overall Control of the Process Electromagnetic Thermal Thermomechanical Flow Analysis Analysis Analysis Analysis
Process synoptic
Process synoptic
Power Supply Network Water Supply Network Capacitor Box Customer Supply Out: 1 1/4 In: 1 1/4 Cooling Unit Equipment Customer Supply L=10m Layout Mold Generator Chiller L=10m Optional Interface L=10m
RocTool Equipment Generator Type - 50kW Generator type - 100kW Work head for 300kW Generator Type - 300kW or Double Zone 2 x 150kW
Surface Quality Elimination of Visible Weld Lines
Surface Quality Combination of High and Low Gloss Possible
Less or No sink Sink marks reduced or eliminated depending on part design and thickness With RocTool Technology Without RocTool Technology
Flow Improvement Flow Improvement and Thin Wall Capabilities BT ADSL Hub with thin wall for LED
Application Examples: Interior Automotive BMW 1 Serie Air Vents Trim Peugeot 208 Decoration Trim and Air vents Audi A8 Centrale Console BMW 3 Series Air Vents Trim
Application Examples: Interior Automotive Renault Zoe Central Cluster BMW 7 Series Rear Entertainment System Citroen C4 Cactus Interior Trim Mercedes Benz S-Class Rear Entertainment System
Application Examples: Electronics Electronic devices Electronic Accessories LapTop A and D covers Smartphones Battery covers and Body parts
Recent Evolution Laser Texturing - Eliminate Secondary Operation - Unique Design Possibilities - New Aesthetics - Brand Recognition (patterns) Surface Oriented Resins - Color / Particles - Durabilty - Scratch Resistance - Chemical Resistance - Additional Features (feel) Induction Heat Injection Molding - Top Surface Quality - Defect Reduction or Elimination - Thinner Walls - Design Functionality - Productivity
RocTool Combined with Laser Etching with RocTool Technology: Better Replication of Mold and Low Gloss Improvement Conventional RocTool Process Technology Case 1 Case 2 Case 3 Case 1 Case 2 Case 3 VDI* Ra (µm) VDI* Ra (µm) VDI* Ra (µm) VDI* Ra (µm) VDI* Ra (µm) VDI* Ra (µm) Mold 22 1.43 24 1.85 27 2.47 Mold 22 1.43 24 1.85 27 2.47 Plastic Part Material: PC Mold Temperature: 80 C/176 F *VDI 3400 (CH) 17 0.8 19 1 22 1.34 Plastic Part Material: PC Mold Temperature: 160 C/320 F *VDI 3400 (CH) 21 1.22 23 1.67 26 2.3
- RocTool Heat & Cool Technology - Top Surface Quality - Combined with Laser Texturing - OEM Proprietary Pattern
MuCell and RocTool Combination MuCell for: MuCell RocTool + MuCell - Lightweighting - Material savings - Dimensional Stability RocTool For: - Top Surface Quality - Process Improvement - Part Overall Improvement
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