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with a decorative coating into the cavity.
This foil which is also manufactured by
Kurz, is aligned accurately during the
closing movement of the mould. At the
same time, a suspended six-axis robot
TX90 from Stäubli picks the PolyIC foils
which are equipped with touch functionality,
out of a magazine as individual
in-mould labels and positions them onto
the mould on the injection side. The
foil is fixed in place in the mould with
0.2mm precision using a vacuum.
The display is then produced by injecting
PMMA through the foil gate using
the variotherm mould temperature control
from GWK. The fully controlled, hydraulic
Systec machine performs the accurate
and reliable injection operation. Its
equipment package for processing transparent
plastics with multilayer screw coating
as well as a four-part, coated nonreturn
valve ensures high melt quality and
therefore the excellent visual qualities of
the component.
The manufacturing cell was designed around a 2,100kN Systec machine. Energyefficient
production is ensured by the dynamic power adjustment of the hydraulic
drive via activeDrive, a combination of a frequency-controlled electric motor and
a highly dynamic variable capacity pump.
During the injection moulding process,
the decorative part of the IMD foil detaches
from the carrier foil and is bonded
onto the front of the component. The
IML functional foil, on the other hand, is
rear injected and forms the back of the
display. That way, a transparent multitouch
display is produced in one shot,
including its decorative frame, whose
wafer-thin contacts provide the connection
for the electronics.
Holistic: clean room module plus
sealed-off working areas
To ensure perfect operation of the multitouch
display, clean room manufacture is
absolutely essential. Therefore, a laminar
flow module from Max Petek Reinraumtechnik
cleans the air drawn in from outside
and prevents the ingress of particles
via an FFU (Filter Fan Unit), achieving an
air purity level of clean room class ISO 7.
However, the cell concept considerably
exceeds the basic requirements of this
clean room class which cover the clean
room module comprising the machine
and the automation area as well as the
use of special, easily cleaned profiles and
surfaces for the protective enclosure of
Numerous modules for robot, foil handling,
clean room, automation enclosure,
conveyor as well as foil cleaning and UV
hardening are working together efficiently
within one cell.
The endless carrier foil with decorative
coating which passes downwards
through the mould, is aligned accurately
within the mould.
A single suspended robot with a multisided
gripper system performs all the
handling tasks involving the component
and the functional label.
The foil feed unit from Kurz which is located
above the mould, ensures the
accurate positioning of the decorative
foil.
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