ReactPro + SpaceA

2019-06-03

Abstract:

ReactPro + SpaceA

One-step Molding, Smart Flexible Manufacturing

Under the rising tidal waves of lightweight construction in the replacement of steel with plastics, the automobile industry is striving to work hard searching for new techniques and technologies to enhance the appearance of the plastic molded products, such as foaming, cladding, aluminum foil decoration, and so on. Among them, polyurethane coating has garnered more and more attention from automobile manufacturers due to its inherent advantages of the technology. It has also been gradually applied to the manufacturing of automobile interior parts, such as dashboards, door panels and so on.

In the upcoming CHINAPLAS 2019, Yizumi will unveil ReactPro, a polyurethane in-mold coating solution. It will carry out a one-step molding of the engine cover with partial high-gloss surface and accommodate SpaceA, a flexible, additive manufacturing system, “printing” a layer of sealing structure. It will undoubtedly be the leading pack in the world to achieve the combination of large-scale injection molding manufacturing and customization.

“Injection Molding + PUR” One-step Molding

To meet the environmental and economic requirements of the automobile industry, Yizumi’s ReactPro will perfectly integrate both injection molding and PUR technology.

On the one hand, the engine cover plate will be produced by Yizumi’s two-platen injection molding machine, UN500DP; while on the other hand, it will also employ the PUR Dosing System & Mixing Head from Frimo Group in Germany. The liquid polyurethane material is made from precise measurement of two component materials (isocyanate and polyols) in proportion and the ensuing chemical reaction. It flows into the PUR unit of the mold cavity under high pressure. After curing, a skin of 0.5mm thickness is formed. The skin is tightly integrated with the engine cover plate in order for the product to achieve a high-gloss and precise appearance.

In this way, ReactPro realizes the fusion of injection molding and PUR in-mold coating technologies in one step, cutting down on the processing steps as well as enhancing the adhesion between the thermoplastic material and PUR surface layer. In February 2019, Yizumi and Frimo Group signed a long-term collaboration agreement on the “Injection Molding + PUR Process Portfolio Technology to jointly develop and sell the in-line portfolio process of thermoplastic components and polyurethane surface.

Innovative Molding Technology InPUR “1+2”

As the pioneeringdomestic provider of polyurethane in-mold coating solution in mainland China, Yizumiinitiates a further insight to consider the economic effects of the solution,adopting an advanced mold technology, the InPUR “1+2”. The mold is fitted withtwo PU cavities and one injection cavity, arranged side by side of each other.After injection molding, the product is transferred to a PU1 cavity. When themold is closed, the polyurethane skin surface is injected in the cavity whilethe next product is then injected in the injection cavity. Thereafter, it istransferred to a PU2 cavity for skin surface injection with the curing of thePU surface in PU1 cavity occurring at the same time. As a result, the two PUcavities can be injected one after the other to form a product with ahigh-gloss surface in a minute without any mechanical turntable.

The InPURtechnology is developed by Germany’s GK Concept, a global technology partner ofYizumi. The technology successfully achieves simultaneous curing and injectionmolding of PU materials in 2 cavities. Different designs can be produced atvarying levels of pressure, temperature and reaction time. As a result, itsignificantly saves on the mass production time. In comparison with themechanical turntable technology, InPUR requires less investment, but generatesa huge output.

伊之密ReactPro主要适用于汽车内饰件（仪表板、门板、A/B/C/D柱等）升级换代

Replacing Traditional Coating Technology with Low-cost Technology

Leveraging on the perfect combination of injection molding and PUR technology coupled with the innovative molding technology, the one-step method of producing a highly effective molding product is finally achieved. Yizumi’s ReactPro significantly reduces the required investment. Unlike the traditional coating technology, the advantages are apparently more superior as follows:

1) Prevents environmental pollution due to coating, more environmentally friendly;

2) Cuts down on the molding steps, shortening the molding cycle;

3) PUR products with thickness as low as 0.5mm can be produced, meeting the design styling requirements in a better way and improving the production output and saving costs at the same time;

4) It is not necessary to add a demolding agent in the entire process;

5) There is less investment for the molding technology in comparison with the mechanical turntable technology;

6) By using PUR materials to prepare for product surface, it can produce a high-quality, tactile appearance (high-gloss surface); at the same time, it is not easily affected by the external environment; additionally, it possesses several quality attributes such as environmental adaptability, scratch-resistant, resistant to chemical corrosion, self-restoration;

Yizumi’s ReactPro is mainly used in the upgrading of automobile interiors (dashboards, door panels, A/B/C/D pillars, etc.), bringing along better texture and showcasing a higher-end premium quality. Simultaneously, there are also unlimited potential in the fields of 3C and home appliances. Its attributes of high-gloss surface and self-restoration performance can bring about more possibilities in the product design.

Seamless Connection to “Additive Manufacturing”, Flexible Production

In the backend processing of ReactPro, Yizumi also make a seamless connection to SpaceA, a flexible, additive manufacturing system, printing a layer of sealing structure on the back of the engine cover.

SpaceA is an innovative product launched by Yizumi, Germany. Embracing the different manufacturing processes as one, it not only can use additive manufacturing (commonly known as “3D Printing”), it can also be combined with inserts, subtractive manufacturing and other processes. As the first in the Chinese market, the miniature KR-6 will be exhibited at CHINAPLAS 2019.

In the industry, there is a certain existential competitive relationship between additive manufacturing and injection molding process. To date, the combination of the two processes expands the boundary of the technology, providing a new path of manufacturing for the enterprises. Both parties can mutually collaborate together.The additive manufacturing will flexibly combine the production chain of injection molding with scalability, printing the functional parts (e.g. the sealing structure, partial reinforcing structure) on the injection molding products and achieving more possibilities for the injection molding products, while at the same time, meeting the requirements of large-scale production and customization for the enterprises.