Munich, June 8, 2010 – KraussMaffei partnered with Evonik Röhm GmbH to develop the CoverForm® process for one-shot production of components with scratchproof coatings. CoverForm® is a cost-effective and resource-saving solution for series production. In the CoverForm® process, a PMMA component is injection molded and a functional layer applied in the mold immediately afterwards. Instead of the conventional value-adding chain – up to 14-steps – for the production of coated parts, CoverForm® is a single in-mold production process, ending with demolding and quality inspection.
The CoverForm® alliance supplies customers with a proven KraussMaffei manufacturing cell < together with the material system, consisting of the substrate material and the reactive coating system, from Evonik. The outstanding material characteristics, especially high resistance to scratching and to chemicals, are essential for parts subject to heavy use, for example, automotive parts or displays for household appliances and mobile phones.
The materials and the process
For the CoverForm® process, the methacrylate specialists at Evonik developed an innovative material pairing of two materials perfectly tailored to each other: a special PLEXIGLAS® cf thermoplastic molding compound for the substrate and a solvent-free, acrylate-based, two-component reactive system for the coating. KraussMaffei optimized its small-volume metering unit to dispense the liquid reactive system into the cavity of the mold mounted on a KraussMaffei CX injection molding machine. The following compression molding step spreads the coating evenly over the PMMA surface.
Innovative engineering – on view in action at the K2010
The CoverForm® process, optimized for industrial-scale series production, will be on show in action on the KraussMaffei booth at the K2010. The hydraulic clamp of the CX 200-750 hybrid injection molding machine incorporates the latest compression molding technology and a metering unit for the reactive system which has been optimized for the CoverForm® process. High-precision control of the electric injector unit enables absolutely repeatable coating with thickness variations in the micrometer range. Moreover, KraussMaffei has further developed its dynamic mold heating system to operate with multiple cavity molds. The compact manufacturing cell is fully automated, with an integrated robot for parts removal and handling. BluePower EcoPac insulating sleeves and the use of BluePower servo drive servo pump technology guarantees high energy efficiency.
With its unique know-how and engineering capability in three key areas – injection molding, reaction processing and extrusion – and its strategy “Technology to the Power of Three”, KraussMaffei has a successful track record in the development of complete multitechnology solutions. The CoverForm® process is one of them. It offers processors the prospect of eliminating the time, effort and costs of intermediate handling, cleaning, and pretreatment of the PMMA substrate, as well as the actual coating and drying processes. Compared with a conventional process, CoverForm® slashes cycle times dramatically, while producing a quality product in a highly stable process.
The CoverForm® system solution slashes cycle times for manufacturing components with protective coatings
CoverForm®: scratchproof and resource efficient
EPS-Download: CoverForm® system solution
