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LATEST ISSUE SGIA Show Preview Assembly Association Technology Focus Management Ask the Expert
CALENDAR October 19-21 October 27-28 November 16-17 April 1-5 2012
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Copyright 2010 Peterson Publications, Inc.
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Abstracts
Decorating
Surface Modification of Inks, Coatings, and Adhesives – The Interfacial Effects
Rory
Wolf, Enercon
It is
well-documented that plastics surface modification techniques can greatly
improve the acceptance of a wide variety of coatings, adhesives, and inks for
improved decoration, painting, and adhesive assembly. By increasing the
hydrophilic characteristics and surface-free energy of plastics, bond strengths
can be improved dramatically. It is theorized that interlayer adhesion between
decorating and assembly formulations also can be improved by applying
atmospheric plasma surface modification techniques. This study examines
experimental data which relates correlations between surface modification and
interlayer adhesions of inks, coatings, and adhesives.
Greener Solutions for Pad Printing
John
Kaverman, Tampoprint
Today’s truly competitive companies are actively searching for environmentally
friendly solutions. This paper will discuss how new technologies have helped pad
printing companies reduce their environmental footprints. Specifically, the
paper will demonstrate how the utilization of electro-mechanical drive systems
in modern pad printing machines and accessories has significantly reduced
utility costs; how advancements in laser-engraved cliché materials have largely
replaced older, chemically-intensive film and cliché developing processes; and
how ultraviolet-curable inks are rapidly gaining popularity over conventional,
solvent-based ink systems in a number of industries due to their lack of an
operational pot-life.
Precision Printed Films and In-Mold Decorating Technologies
Tom
Robinson, Nissha
In-mold decorating (IMD) refers to any process where a part is decorated in some
manner “in-mold” or within an injection tool. The in-mold decorating industry is
now, and for the foreseeable future, dominated by processes using printed films,
sheets, and foils within the injection molding cycle to manufacture molded and
decorated components. This paper will be focused on the strengths and
limitations of various precision-printed films used in in-mold decorating
technologies and how they compare to other decorative processes. This paper also
will cover some of the aspects of the associated system components and
peripheral equipment required for an effective advanced in-mold application.
Plastics Laser Marking and Machine Vision Codes for Product Security and
Traceability
Plastics manufacturers have an exponentially growing demand for indelible
marking identification using machine vision codes for product security and
traceability. Direct part marking of variable information data enables tracking
a product from the time of manufacturing until the end of its useful life, which
is critical for component traceability and security. New advancements in laser
marking and machine vision technologies offer unprecedented capabilities for
micro-marking 2D Data Matrix codes on virtually any plastic product achieving
unit level identification (UID). Post 9/11, manufacturers are implementing
strategies to establish traceability and thwart product tampering and
counterfeiting for products including automotive, electronic,
medical/pharmaceutical, packaging consumer goods, and more.
Heat
Transfers: The Whole Story
Eric
Steinwachs, ITW United Silicone
Heat
transfer decorating is one of the most popular forms of product decorating today
for customers looking for a simplified, cost-effective, high-quality graphics
solution. However, there are many types of heat transfers available today and
each one has its own unique set of advantages and limitations. This presentation
will examine the various types of heat transfers that exist in the market and
compare and contrast the similarities and differences between the technologies.
Included will be a look at the manufacturing process and history of screen,
wax-release, and digital heat transfers.
Exterior UV Curable Topcoat for Physical Vapor Deposition Applications
Jennifer Smith, Red Spot Paint & Varnish
Coatings for multi-purpose decorative and automotive lighting PVD applications
have been used in the UV curable coating industry for over twenty years.
However, these coatings do not have the required durability to replace chrome
plating. Recent developments with a UV-curable topcoat for PVD provide the
performance characteristics needed to pass the OEM’s toughest requirements. This
paper will address the current chrome plating process and the challenges
associated with developing durable coatings for PVD applications. It also will
provide an explanation of how the UV and PVD materials are applied, a list of
advantages that the UV/PVD decorative process encompasses, and targeted end
applications.
Flame
Plasma Surface Treatment – An Ecologically-Based Alternative to Conventional
Treatment
Methods
Joseph DiGiacomo, Flynn Burner
Corporation
Adhesion promotion is used across a wide industrial spectrum in painting,
decorating, labeling, and de-flashing of polymers. Adhesion promotion
technologies have wide application in the automotive industry for such products
as bumper fascias, door and instrument panels, and fire walls. Flame plasma is
one method used to modify the plastic surface of these and other polymer
products, as well as to promote adhesion of coatings, adhesives and labels. This
paper will describe the theory behind natural gas, propane or LPG- fired flame
plasma surface treatment to promote adhesion of water-based inks, coatings,
adhesives, labels, and other substrate laminates to polyolefin-based (PE and PP)
substrates. Critical parameters in flame treatment are flame chemistry, flame
geometry, plasma output, and distance of the burner to the part. The
interrelationship between these variables and how to control them for optimum
surface treatment will be discussed. The use of Schliren imaging technology,
high-speed photographs of the flame geometry used to develop new burner designs,
as well as advances in equipment technology will be presented.
Evaluating Your Decorating Alternatives for 3D Plastic Parts
Ben
Abner, Inkcups Now
With
new decorating methods available for decorating plastics, determining the best
method must require careful analysis. This presentation will discuss both new
decorating technologies (including digital ink jet) and more traditional
decorating choices, such as pad and screenprinting. It will outline the
advantages of each type of decorating process for specific applications and will
cover what may be the most cost-effective method for a particular plastic part.
Decorating Methods for Injection-Molded Parts
Dennis
Northrop, Soliant LLC
This
paper will discuss several various decorating methods for injection molded
parts, including in-mold foils, in-mold laminates, paints, hydraulic coatings,
and form over part (FOP). Descriptions and a comparison of the various methods
will be discussed. It will cover basic process descriptions, definitions,
advantages of each, and their relationship to part design and end usage. How do
I select the decorating method most suitable for my part?
Automotive Plastics Case Radio with Insert Molded EMC Shielding
Paul
Uglum, Delphi Corp.
Innovation is critical in remaining competitive in the plastics industry. The
innovative use of an insert-molded Faraday cage which allowed the up integration
of many assembly and design features will be discussed. This design enabled the
use of slide lock and snap lock features that reduced the required assembly time
and eliminated 29 fasteners. The process of identifying opportunities for
innovation and developing solutions will be reviewed. Tools for risk mitigation
such as DRBFM and strategies for protecting innovations will be discussed.
Energy
Saving Advancements for Painting Systems
Rob Brewer, Thierica Corp.
The
challenge for manufacturers to stay competitive with the growing pressures to
reduce energy consumption has led to several design advancements specific to
paint systems. This paper will discuss how new advancements with thermal cure
ovens to dry painted material, air handling equipment to provide a controlled
paint environment, and abatement equipment sometimes used to destroy volatile
organic compounds will help reduce energy consumption and yield the best savings
for today’s painting systems.
Non-migrating, Low Coefficient Friction Coating
Bob
Umland, NuSil Silicone, Tech.
Silicone elastomers inherently have a high degree of surface tack, which may
cause problems in applications where they come in contact with each other or
other surfaces. Lubricious coatings can be used to reduce blocking between
silicones, but they also have the potential to migrate from the substrate due to
their fluid-like consistency. Therefore, there is a need for a permanent, low
coefficient of friction coating that can be applied to silicone elastomers.
NuSil has developed a coating, which, when sprayed and cured with heat, will
reduce the coefficient of friction of the underlying silicone surface. This
material underwent static and kinetic testing that demonstrated a significant
reduction in the surface COF and an increase in abrasion resistance of silicone
elastomer substrates.
Automated Low Heat Curing for Small Area Applications
Mike Kay, EXFO Life Sciences and Industrial Division
Light-curable coatings and adhesives are commonly found in many assembly
processes. Benefits such as near-instant cure, lower energy consumption,
environmentally friendly, and higher productivity make a compelling argument for
this technology. EXFO brings new innovative light sources for automated curing
of coatings or adhesives on sensitive substrates where a key requirement is the
elimination of any heat. These light sources are available in a very narrow or
broadband spectrum depending upon the application. The systems are designed for
small area applications (under 3”) and provide a very uniform cure area with a
minimal footprint making it very easy to integrate into any automated system.
Developments in Inkjet Technology for Decorating Polymeric Products
Paul
McGovern, Mimaki USA
During the last decade piezoelectric drop-on-demand inkjet has gained
considerable success and there has been an explosion and proliferation of new
applications for wide range of industrial applications. Success in fluid
formulation (UV, Solvent) and system designs have allowed plastic manufacturers
to leverage the flexibility inherent with digital printing to provide
customization of mass produced products and high resolution printing of a wide
variety of flexible and rigid plastic product applications. UV inkjet technology
is ideal for multi-color (CMYK + 2) printing variable information for branding,
logos and process color decoration. This paper will provide an overview and
describe the major developments in inkjet ink chemistry, print head design, and
systems integration. Examples of using inkjet technology to deliver high quality
printing onto plastic packaging products will be described and illustrated.
Assembly
Aesthetic Assembly – The Art to Attractive Bonding
Miranda Marcus, Dukane Corp.
After
carefully molding a beautiful product, nothing is worse than seeing it destroyed
during assembly. Every joining
process is capable of causing marking, flash, particulate, damage to appendages,
or other aesthetic defects. This paper will discuss how proper part design and
processing can make a finished weld imperceptible or even a cosmetic asset. The
art of attractive bonding is specific to each process or type of product.
Whether processing parts through ultrasonic, spin, vibration, hot plate, laser
welding, or thermal staking, methods do exist to improve the appearance of the
overall product after bonding.
Welding of Bio-Plastics
David
Grewell, PhD, Iowa State University
With the growing demand for environmentally friendly bio-renewable resources,
there has been a parallel growth in the development of bioplastics. These
include commercially available starch-derived plastics and plastics derived from
renewable oil and proteins. As with any plastic, these new materials must often
be joined to produce final products. This paper reviews impulse and ultrasonic
welding of PLA, as well as friction welding of plant protein-based plastics. It
has been found that each of these plastics can be welded with weld strengths
matching the parent material strengths.
Benefits of Force Profiling – Case Study
Sophie
Mornea, Branson
The
benefits of force profiling will be discussed, which includes the ability of
achieving a hermetic seal when ultrasonically welding hygroscopic material. The
paper will cover the difficulty associated with these materials, how they are
prone to cavitations during welding (which creates air bubbles in the weld
joint), and how force profiling can be used effectively to eliminate these air
bubbles in the weld joint at the opportune time during the weld cycle.
Advancements in Induction Welding Process
Steve
Chookazian, Emabond
Induction welding of thermoplastics is a design and assembly method that
provides a simple, rapid, and reliable assembly technique to produce structural,
hermetic, or high-pressure welds on most thermoplastic materials and TPEs. This
presentation will include a basic overview of assembly method options, induction
welding process principals of operation, process benefits, and material
selection, as well as joint and part design. It also will discuss several
application examples, including demanding leak-proof and high-pressure
applications.
Evaluation of Ultrasonic Welding Results Using Microscopy
Ken
Holt, Herrmann Ultrasonics
The
evaluation of ultrasonically welded plastic assemblies can be accomplished
accurately using relatively simple techniques. Common lab and “hardware
store-type” equipment can be used to visualize the welds in the interface of the
two welded parts and determine the condition of the welding, the degree of
consumption of the intended welding joint, and any problems that may be
occurring in the area. A thorough understanding of the welding of a particular
assembly can be made when this is done and tracked to specific welding parameter
sets and data.
Laser
Welding – Markets Open As Innovative Methods Emerge
Jerry
Zybko, Leister Technologies
Adhesive Selection for Effective Plastic Bonding
Anne
Forcum, Henkel Corp.
As manufacturers expand the amount of plastic components within their parts, it
becomes more important for the manufacturers to be able to effectively and
efficiently join these components for a complete assembly. With the wide variety
of adhesives currently available, it can be challenging to select the correct
adhesive for a specific plastic bonding application. This presentation will
discuss the seven families of adhesives proven to be effective in bonding a
variety of plastic substrates and how each family offers a unique combination of
performance and processing properties. Topics covered will include
identification of plastics most widely used in the manufacturing industry,
adhesive selection guidelines for plastics, and surface treatments for ‘hard to
bond” plastics.
Structural Bonding of Plastics
Anne Forcum, Henkel Corp.
When designing assemblies made from or including plastics, it often is critical
to structurally hold assemblies together with a reliable mechanism. Plastics can
be fastened reliably to a wide variety of substrates using an engineered
adhesive solution. This paper will cover how adhesives have been successfully
used to displace solvent welding for a variety of applications, join dissimilar
substrates, and provide structural integrity to a wide variety of products and
applications. It also will discuss design considerations and available
structural adhesive technologies.
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