A new line of Yellow Jacket rubber extruders are designed and manufactured to meet the special challenges that are presented in the precision processing of rubber into extruded tubing, profiles, wire insulation, cable coating, sheet, film, rod, and many other extrusion applications. Standard screw sizes in inches are 5/8, 3/4, 1, 1-1/4, 1-1/2, 1-3/4 ,2, 2-1/2, 3-1/2, and 4-1/2. The company has incorporated many features to aid in the precision processing of rubber. The slide-mounted roll feed has been designed to aid in the feeding of the rubber strips to the extruder screw and has its own ratio-controlled drive system that is electronically linked to the extruder screw drive. Water-cooled feed sections are available in standard, tangential, and tapered ID styles and are said to be easily changed for different rubber materials. Electrically heated/water-cooled cast heaters are used on the barrel for easy maintenance and temperature stability. The closed-loop water cooling system features microprocessor-based controls, flow valves, recirculating pump with reservoir, and a heat exchanger.
Wayne Machine & Die Co.
A new brochure explains how designers, processors, and OEMs can differentiate their products, create new product lines, and increase profit margins by using Santoprene® TPE for a variety of grip applications. Citing numerous grip applications from around the world, Getting a Better Grip with Santoprene TPE details how many companies have used Santoprene TPEs in their products to add manufacturing, retailer, and consumer value to products such as sporting goods, kitchenware, hand and power tools, personal care products, lawn and garden equipment, appliances, consumer electronics, and office supplies.
Ergonomic testing data of grip materials confirms that Santoprene TPEs are superior in areas of friction, grip effort, surface texture, perceived control, finger comfort, and hand comfort in comparison with grips made of steel or polypropylene, according to the supplier. Other attributes include variable finishes and textures, soft-touch, durability, resistance to heat and various fluids, food standards compliancy, dishwasher and microwave safety, low vibration, and non-slip surface.
Information on Santoprene 8000 TPE grades explains the benefits of improved colorability, non-hygroscopicity, low residual halogens, and low coefficient of friction. From a manufacturing perspective, the processing advantages of using Santoprene TPEs to produce dual-hardness grips are described in detail. Grip design guidelines, including attaching overmolded grips and separately molded grips, are illustrated. For designers, useful information on process selection identifies the special grades of Santoprene TPEs that bond to materials, such as nylon (PA), ABS, PC, PS, ASA, PMMA (acrylic), PET, and PPO, enabling increased design flexibility. The brochure also takes designers, processors, and OEMs through the product development process and details the professional resources available from the company.
An expanded line of specialty closures, seals, and stoppers specifically developed for demanding laboratory and specialty packaging applications are described in a brochure. The range of products and applications include PTFE/silicone septa for chromatography and environmental analysis, heat sterilizible cap liners for pharmaceutical and medical device packaging and hydro-phobic, and gas venting cap liners. Also described are high-performance micro-array, multi-well cap mats, and laboratory and serum vial stoppers.
A new Telcar® thermoplastic olefin (TPO) compound for flexible cord insulation has received an Underwriters Laboratories (UL) component recognition for wet-location uses, as has an established, harder grade of the same TPO. The two TPO compounds are Telcar 3050 (with 75 Shore C Durometer rating) and the new, softer grade Telcar 3050-88 (88 Shore A). Tested in water for 7 days at 65°C (149°F), the 3050 grade retained 99 percent of original tensile strength and 103 percent of original elongation, with weight change and volume swell of +0.38 percent and +0.34 percent, respectively. The same grade exhibited a -60°C (-76°F) brittle point (ASTM D-746). The UL component recognition for these compounds makes them suitable for submersible pump cable and SE, SJE, and SVE flexible cords with minimum insulation thickness of 30 mils and a wet rating of 75°C (167°F).
Three new resin systems, the RTP 2700 U, 2700 S, and 2800 B Series, combine the functional performance and properties of conventional thermoset rubbers with the processability of thermoplastics for an excellent balance of physical properties and economics, according to the supplier. With shore hardnesses ranging from 30 A to 75 D, the new systems can reportedly be formulated with properties to increase strength, impart flame retardancy, provide conductivity, and alter appearance through special effects coloring. All property enhancements are done during the initial compounding phase, which means they have a single heat history. Engineered to be compatible with a variety of rigid thermoplastics, the new systems reportedly give designers flexibility in overmolded soft touch and ergonomic applications such as grips, handles, tools, gaskets, seals, hoses, bumpers, strain reliefs, electrical boots, and wheels. They are said to permit the fabrication of “rubber-like” articles with the speed, efficiency, and economy of injection molding, extrusion, or blow molding.
The H48 200-ton horizontal injection machine features the company's enhanced G8 controls, an increased 34-oz shot capacity, and 450 mm x 450 mm (17.71 in x 17.71 in) platen size to accommodate larger parts. A completely redesigned frame, injection unit, and footprint reportedly enables molders to install dual brushing systems, automatic part ejectors, gripper systems, and even multiple part removal conveyors under the machine. The onboard PC and control panel are positioned closer to the mold for improved ergonomics. The G8 control reportedly combines a faster CPU and more efficient control loops to reduce cycle times up to 25 percent over competitive presses. Users can utilize the PC's ability to store multiple parts programs or download them on a LAN. Operators can see any machine parameter's set and actual values, in plain language (English or others) and real time. The press can be fitted with mechanical or up to three hydraulic ejectors to increase automation and lights-out operation of the unit.
NexPrene® rubber (TPV) is a fully vulcanized EPDM/PP thermoplastic vulcanizate. It is designed as a replacement for thermoset elastomers such as EPDM and Neoprene. NexPrene is also said to be an alternate to Santoprene® TPV. It is available in natural, black, or pre-colored in a hardness range of Shore 55 A to Shore 50 D. Due to its excellent UV resistance, NexPrene TPV is recommended for various industrial applications, including building and construction, medical, and consumer products.
A new brochure describes how light curing resins for PCB assembly lower manufacturing costs while maintaining or improving end-product quality. The brochure features processing information as well as pictures and descriptions of typical applications, including conformal coatings, potting materials, encapsulants, tacking resins, and masks. Also listed are a variety of features, benefits, and agency approvals which reportedly differentiate the adhesives from slower-setting resins. The coatings, encapsulants, and masks are said to cure faster than ever and incorporate a number of features not available in other light curing coatings.
Bayfol® CR polycarbonate (PC)/polyethylene terephthalate (PET) polyester film provides a gloss/micro-matte finish for membrane switch applications—such as kitchen appliance control panels with see-through windows—that reportedly allows easier embossing and improved ink adhesion. The Bayfol CR film is said to be the first material in the membrane switch market to compete with PET films for use in see-through window applications found on microwaves, ranges, washers, and medical IV monitoring equipment. The Bayfol material is reportedly able to overcome problems that have affected PET-only membrane switch overlays, such as faceplate cracking.
To develop the new Bayfol CR film, the company utilized Makrofol® PC film technology to create a PC/PET blend that is said to feature the dimensional stability of polycarbonate resin and the excellent chemical resistance of PET film. Bayfol CR film is available in gauges of 0.005 or 0.007 in (0.127 or 0.178 mm) and in rolls of up to 36.5 in (927 mm) in width.
The new OmegaRim RX and RimCell RX reaction injection molding (RIM) lines are said to feature significant improvements, including the addition of Rexroth A2VK positive displacement axial piston metering pumps for volume and ratio accuracy; open construction and straight tubing runs for faster, easier maintenance with minimum downtime; and accurate digital flow readout that reportedly eliminates the mess and inconvenience of wet calibration.
The RimCell RX line is said to offer a mechanism that allows the motor to slide away from the pump, with a mounting bracket that doubles as a seal-changing workbench—reportedly an industry first. The mechanism is said to streamline maintenance by making pump unbolting and extensive chemical tube disassembly unnecessary and saves hours of production downtime each time the pump seal needs to be replaced.
Formerly, gas assist molding technology was dominated by the processors of thermoplastics, according to the company. Its new Gas Evacuation Technique (GET), however, is said to offer molders of bulk molding compounds (BMCs) similar cycle and weight savings benefits. The company has developed a method of evacuating the center of thick, cross-sectioned injection molded designs. Unlike standard thermoplastic GAIM methods, the company uses a new technique made possible by the unique processing characteristics of the composite. By filling a die completely (as processors would do in standard molding operations), the pressure and heat associated with thermoset molding begins to cure the part from the outside in. By maintaining standard molding conditions for a pre-set amount of time, the BMC component's surface hardens, while remaining soft on the inside. Based on a study of time and temperature, the thickness of this “hardened” shell can reportedly be controlled. When the desired wall thickness has been obtained, a gas port mounted in the mold cavity is pressurized. This results in the uncured BMC being forced out through the center of the gate, runner, and sprue. The material is reclaimed in the press nozzle and mixed with virgin material as the next charge is plasticized. The result is said to be a hollow BMC component that requires 40 percent less material and 70 percent less clamp time.
Plastic caps and plugs are utilized in many appliance applications. The wide variety of sizes, shapes, and colors offered make them suitable for thread protection, packaging component pieces, finishing, and product identification. Their snug fit reportedly provides an excellent means of keeping foreign contaminants off of a product. Custom molding is available, and a choice of several formula hardnesses is offered. Products range from 0.062- to 6-in (1.57- to 152-mm) diam.
The new Praxis Series of vertical injection molding machines features an innovative design, two-platen concept, and ergonomic features. The Series will include six models, ranging from 60-380 tons, with the first two introductions being two-platen, the 280-ton and 380-ton models. Among the machines' key design attributes are a new clamp design, a large-diameter rotary table, a rotating ram injection unit with pivoting capabilities, and a modular design.
The supplier is also offering a new class of Caliber Series machines. A 500-ton model is available, a 700-ton model will follow later this year, and a 950-ton model will be unveiled during the first quarter of 2003. The Caliber Model 500 machine features reduced floor space requirements, generous mold specifications, and simplified hydraulics.
Furthermore, the company has expanded its IntElect Series of all-electric drive injection molding machines. The second and third members of the series are a 50-ton and an 80-ton model, which are in addition to the previously announced 110-ton model. According to the company, the three models share many features. For example, they use an identical electric drive toggle mechanism, plus time-tested belt and ball screw technology. The only thing that's different among the 110-, 80- and 50-ton IntElect Series models is their size. Seven more IntElect models ranging from 165-625 tons will be introduced in the near future.
Van Dorn Demag Corporation
PEEK-HT™, a high-performance polymer, is suitable for applications requiring superior high-temperature resistance, such as heat exchanger parts and industrial valve linings. With a glass transition temperature of 315°F (157°C) and a melting temperature of 703°F (373°C), the semi-crystalline, unreinforced polymer reportedly offers all the key characteristics of standard PEEK™ polymer, including toughness, strength, and chemical resistance. PEEK-HT polymer's high-temperature performance, however, is said to surpass that of standard PEEK™ polymer. It reportedly has the ability to retain mechanical and physical properties to temperatures more than 50°F (10°C) higher than the standard PEEK™ polymer, and it reportedly has up to three times the wear resistance at high temperatures. Additional benefits include long-term creep and fatigue resistance over a wide temperature range. The polymer also has a substantially higher tensile strength and flexural modulus at 482°F (250°C) versus the standard PEEK™ polymer, according to the supplier.
The company's engineered materials include multi-component blends of ionomers, urethanes, and nylons to produce materials that meet specific performance requirements, regardless of the base resin. Among the products offered are Formion® formulated ionomers, which are said to be a class of polyolefins that offer toughness, abrasion resistance, chemical resistance, and weatherability. Available in reinforced and nonreinforced grades, the compounds reportedly offer a full range of stiffness and gloss properties and, in certain applications, are able to displace the need for painting. Polyfabs® ABS compounds offer a broad range of products that will reportedly meet or exceed a wide spectrum of specifications. Polyfabs is available in general-purpose molding, high-impact, glass-reinforced, high-heat, alloyed with either polycarbonate or ASA, and extrusion. The material can be purchased either in natural or pre-colored formulations. Other materials offered include Polyflam® flame-retardant thermoplastic compounds and concentrates; Polypur® thermoplastic polyurethane compounds; Schuladur™ filled and unfilled thermoplastic polyester compounds; Schulamid® filled and unfilled nylon compounds; Lybrilon® lubricated, lightweight, corrosion-resistant materials; Polystat®/Comshield® EMI/RFI anti-static materials; Tempalloy® high-temperature materials; Thermex® heat-dissipation materials; Aqualoy® hydrolytically stable materials; Comtuf® impact-resistant materials; and Hiloy® high-strength materials.
The company's magnesium injection molding (MAG) services are said to produce components with attributes that include superb quality, high repeatability, dimensional precision, and design flexibility. The magnesium injection molding process is reportedly similar to plastic injection molding, with mechanical properties equivalent to or better than die-cast components. Combined with the knowledge, expertise, and ability of the company to mold plastic and magnesium, is the capability to mold powder metal. Metal injection molding (MIM) has reportedly become one of the best processes available to produce complex metal parts characterized by superior surface finishes, excellent corrosion resistance, a reduced need for secondary operations, and material properties comparable to wrought. The company's magnesium molding capabilities include conventional single shot, overmolding with plastic, and insert molding.
The company's new Scotch Mini-Weld adhesives are packaged in 2-oz, plastic cartridges and come with a new dispensing system. The complete system is said to make the adhesives easy to handle and suitable for use in applications where load-bearing strength with the speed of a hot-melt bonding system is desired in a portable size. Available in three formulations, Scotch Mini-Weld adhesives feature quick heat-up times, low temperature application (190°F-220°F) and a long and efficient heat life. The adhesives also combine many of the features of the company's Jet-Weld adhesives (polyurethane reactive hot melts) and contain no solvents. A starter kit includes a Mini-Weld adhesive heater, carrying case, applicator, and three adhesives.
The RIM-Star ECO II polyurethane mixing and metering machines are available as pump-design in the following versions-Standard S machine (measurement), M-machine (measurement and process-data acquisition), and C-machine (measurement, recording, and closed-loop control). The machine is reportedly cost-effective and compact, provides excellent production and processing reliability, features daytank technology, is easy to maintain and service, is space-saving and easy to move around, and incorporates the plug-and-play principle. The machine, complete with daytanks, is mounted on a frame and can be moved to the production site by forklift truck. Once the mixing head has been assembled, the machine is ready to start production. The RlM-Star ECO II range operates on the environmentally friendly high-pressure principle. The price/performance ratio reportedly renders these machines particularly interesting for those application areas covered by low-pressure machines. The design of the RlM-Star ECO II is based on structural modules, which have reportedly proven their reliability over long periods within the company's machinery program.
Krauss-Maffei Kunststofftechnik GmbH
The 752V-SS dispense valve's accurate deposits and clean, drip-free cutoff increase productivity, improve appearance, and reduce downtime when dispensing UV-cure adhesives on automated and semi-automated assembly lines, according to the supplier. The pneumatically operated 752V-SS valve is said to provide exceptional accuracy and reliability with minimal maintenance. It features a design with no seals or O-rings to wear out and leak. Instead, a precision diaphragm rated for tens of millions of cycles reportedly ensures long, trouble-free operation. A fast, clean cutoff at the end of each cycle eliminates waste, dripping, and cosmetic damage. The valve is said to be compact, lightweight, and simple to install, and, therefore, is suitable for automated assembly machines, XYZ tables, and retrofits on existing production lines.
STYRON™ A-TECH™ advanced polystyrene resins, the next-generation line of the company's polystyrene products, reportedly offer a balance of toughness, gloss, stiffness, or flow in combinations that are said to improve end-use performance, while helping customers reduce overall costs. A complete line of STYRON A-TECH advanced polystyrene resins are offered for large and small appliance applications.
One product is the STYRON A-TECH 1170 resin series, a family of high-impact, environmental-stress, crack-resistant (ESCR) resins for refrigerator liners and other deep draw extrusion thermoforming applications. The resin series includes STYRON A-TECH 1175 polystyrene in Europe; STYRON A-TECH 1170 polystyrene in North America and Latin America; and STYRON A-TECH 1173 polystyrene in Asia Pacific. The resins are designed to improve extruder output and thermoforming speeds for greater productivity and cost performance. They are also said to distribute more uniformly throughout the part to allow for downgauging, while still providing toughness and ESCR to foodstuffs and blowing agents to maintain the integrity of the part.
The company also offers additional STYRON A-TECH resin products with unique combinations of toughness and gloss for great design flexibility in shape, color, and finishes in appliance applications.
Dow Plastics, a business group of The Dow Chemical Company and its subsidiaries
Washer Pull Plug
The company offers a two-piece washer pull plug that can reportedly be installed to a part in just two steps. The first step is to slip the pull plug piece into the bore. The ring located at the base of the plug will center and secure the piece. Once the ring connects to the inside of the bore, the plug base completely seals off the one edge of the part. The second step is to seal the other edge, slide the washer, lipped end first, over the pull plug handle. The handle and washer are then pulled away from each other until the washer glides over the barb and the lip squeezes its way into the opposite bore. The chamber on the lip reportedly eases installation to the part. The barb holds the two masks tightly in place to prevent blow offs. Both sides of the part are then reportedly fully protected. Removing the mask is said to be just as fast and as simple as installing it. The washer and large plug handle are reportedly easily pulled away from each other, and the handle's hollow cavity reportedly allows for quick and easy removal. The handle flexes and shrinks as the washer is pulled off.
The new MQS series micro-switches from the company feature UL94V0, high tracking index (CTI-250V), and have a variety of contact ratings. With an operating temperature up to +150°C, the new series meets UL, CSA, and VDE standards. The micro-switches are available with operating force from less than 15 g to 400 g and are available with standard quick connect terminals, right-angle PCB pins, RAST-5, or solder lug terminals. According to the supplier, the MQS series is well suited for industrial and consumer applications that require long life and high reliability.
The company's Load Measuring Pins are based on highly accurate and reliable full-bridge strain gauge technology, with full temperature compensation. They are said to be a cost-saving solution for precise load or overload measurement in harsh industrial environments. Standard models include the LB Series (mV output) and the LE Series (integrated signal amplifier), available in 10 standard capacities from 2.5-2,500 kN (0.28-281 tf). All are made of rugged, tight construction and high resistance stainless steel, with standard options including lubrication, cable length, and output connector type. Special options include an IP 68 hermetically sealed, waterproof version, OIML certification, and special material testing and certification for use in low temperatures or areas where x-rays are present. Upon request, load pins can also be custom designed and mounted on new or refitted installations.
The company added enhanced remote control to its microprocessor-controlled a.c. hipot tester, model 2510. Enhanced remote control was designed to allow integration into a fully automated testing environment. The enhanced remote control utilizes remote inputs to allow a user to send signals for test and reset, enabling the test cycle to be run remotely. Pass, fail, and processing signal outputs can also be monitored remotely by the user. Additional safety precautions have been added, including a remote safety interlock function. This function, designed to enhance operator safety, can be connected to a test guard station, which must be closed in order to allow a test to start. This will disable the test cycle, including the high voltage output unless a safe condition is detected. The 2510 provides test voltages up to 5,000 V a.c. and adjustable trip currents up to 10 mA.
Loctite® ZETA® 7730, a new high-performance UV cure wand system, is designed for spot curing applications. Offering up to 4 W/cm2 of UV light at 320-410 nm, the system is said to deliver fast cure cycles and tack-free surfaces when used for light cure adhesives. It utilizes an autoranging 60-265 V a.c., 50-60 Hz solid state power supply, a 50-W metal halide lamp, and a liquid light guide (light guides sold separately). Typical cure area is 0.5 in (12.7-mm) diam. The exposure cycle begins once the system's foot switch is actuated. Exposure time is controlled by either a programmable timed mode—0-99.9 sec—or a manual mode, where the shutter remains open as long as the foot switch is depressed.
The new ROBOformER® is said to be the world's only robotic bending cell with advanced, intuitive software to orchestrate the movements of robotic loading, intricate bending actions, and unloading. The software reportedly provides instant, real-time management of the robot simply and immediately. With one cell, one controller, and one programmer, the ROBOformER is said to be the solution for low-gauge sheet metal bending challenges, taking production from drawing to finished product in about an hour, without stopping the machine. The software uses a solid modeler and a specially designed user interface that allows solid drawings to be imported/exported, manages an advanced tool file that can suggest press set-up solutions, determines the optimum bending sequence, and anticipates potential interference. In addition, it also is said to automatically generate optimized robot trajectories, optimized and synchronized press-brake movements, and workpiece loading/unloading. The six-axis robot can handle a maximum load of 176 lb (80 kg), and the pressbrake features sheet metal bend length 122/166 in (3,100/4,100 mm), and bending force of 117/151 tons (1050/1350 kN) with a maximum bending speed of 47 ipm (20 mm/s).
The new CR Series power rocker switch with 20-A switching capability uses heavy-duty silver alloy contacts to perform high-current switching in a 1 1/8-in (L) x 1/2-in (W) x 1-in (H) package. Typical applications include appliances, office equipment, and lighting control. The CR series is available in a wide variety of colors in both lighted and non-lighted designs. Typical lighted designs employ neon bulbs for use at 125 V a.c. or 250 V a.c. Lighted versions for d.c. operation are also available. Within the non-lighted family, options include single-throw and double-throw devices, and a two-color molded button with bright red secondary color for optimal visibility at a distance. Recommended panel cutout length is 1.12 in (28.4 mm), and the series can accommodate three different panel cutout widths: 0.476 in (12.09 mm), 0.528 in (13.41 mm), and 0.543 in (13.79 mm). The maximum operating temperature is 85°C (185°F), and standard termination is accomplished with quarter-inch (0.248 in x 0.031 in) quick-connect tabs.
The MRC300 is a 300-W, dual-voltage 115/230 a.c., free-standing thermoelectric liquid chiller used in many applications, including laser, medical, and laboratory. It measures at 13.8 in x 8 in x 13.5 in (350.5 mm x 203.2 mm x 342.9 mm), and weighs 30 lb (13.6 kg). Standard features include pump, reservoir, low fluid level detector, and 7-ft (2.1-m) detachable power cord (with plug) available in three global configurations. Also featured is an integrated solid-state temperature controller that can stabilize fluid temperature to within 0.25°C (32.4°F). The controller is available in two serial port configurations. This solid-state chiller is designed to use water or a coolant solution and reportedly offers a variety of benefits over traditional compressor-based chillers such as no CFCs, 300 W of cooling (at ?T=0), compactness, quietness, lower maintenance, high accuracy control to ±0.25°C (±32.4°F), RS232 or RS485 serial communication, and low cost.
A new line of high-precision NTC thermistors feature temperature precision of ±/-0.3°C (32.5°F), making them suitable for applications that require extremely accurate temperature control compensation. The new thermistors are said to provide low cost, high stability, and excellent thermal cycle endurance, as well as small ß value tolerance and resistance. They reportedly require no adjustment between the control circuit and the sensor, feature an operating temperature range of -50°C to 110°C (-58°F to 230°F), and are available in all resistance-temperature (R/T) curve materials. Resistance values at 25°C (77°F) are available from 1K ohms to 47K ohms. Standard tolerance ranges are ±1 percent, ±3 percent, and ±5 percent. Dissipation value is 2 mW/°C in still air with a typical thermal time constant of 15 sec. Maximum power rating is 10-15 mW at 25°C (77°F). The series is manufactured with 0.20-in (5-mm) tin-plated leads and a chip coating of black epoxy resin. Leads measure 1.023-in (26-mm) in length with chips of 0.118 in by 0.138 in (3 mm x 3.5 mm).