Advanced Thermoforming: Methods, Machines and Materials, Applications and Automation

344 Pages·2012·4.258 MB·English

by  Sven Engelmann(auth.), Richard F. Grossman, Domasius Nwabunma(eds.)

Advanced
Thermoforming
Wiley Series on Polymer Engineering and Technology
Richard F. Grossman and Domasius Nwabunma, Series Editors
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Advanced Thermoforming: Methods, Machines and Materials, Applications and
Automation
Sven Engelmann
Advanced
Thermoforming
Methods, Machines and
Materials, Applications
and Automation
Sven Engelmann
Director of Polymer Technology
Gerhard Schubert GmbH
Crailsheim, Germany
A John Wiley & Sons, Inc., Publication
Copyright © 2012 by John Wiley & Sons, Inc. All rights reserved
Published by John Wiley & Sons, Inc., Hoboken, New Jersey
Published simultaneously in Canada
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Library of Congress Cataloging-in-Publication Data
Engelmann, Sven.
Advanced thermoforming : methods, machines and materials, applications and automation by / Sven
Engelmann.
p. cm.
Includes index.
ISBN 978-0-470-49920-7 (cloth)
1. Thermoforming. I. Title.
TP1151.T48E64 2012
668.4'23–dc23
2011037218
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1
For my lovely wife Ulrike
and my wonderful children
Leo, Peter, and Luzy.
Contents
Preface xi
1. Introduction 1
2. Basics of Thermoforming and Thermoplastics 5
3. Production of Semifi nished Products, Extrusion,
and Coextrusion 12
4. Introduction to Technical Parts 28
5. Antenna Radome Manufacturing 29
6. Fuel Tank Production on Sheet Machines 33
7. Automotive Body and Commercial Vehicle Applications 41
8. Production of Refrigerator Liners 48
9. Paint Replacement in Automotive Applications 61
10. Motor Air Intake Made from PA 6 GF 15 70
11. Sanitary Equipment (Sheet Machine) 72
12. Thermoforming and Milling of Large-Scale Formed Parts
(Sheet Machine) 76
13. Changeover of Sheet Machines 84
14. Chromed Parts 92
15. Applications in Aircraft and Mass Transportation 94
16. High-Quality and Fully Transparent Products
(Sheet Machines) 103
17. Deco Molding and Multi-deco Molding 106
vii
viii Contents
18. Automotive Body Parts Made of PA + ABS 119
19. Softfeel Made from ABS/TPU Material 121
20. Introduction to Packaging 124
21. Optimizing a Thermoforming Process for Packaging 125
22. Analysis of Thermoforming Films 137
23. Advanced Analysis of Thermoforming Films 144
24. Analysis of Thermoformed Products 151
25. Analysis of Completely Formed, Filled,
and Sealed Containers 160
26. Automated Packaging 167
27. Production of Flowerpots 179
28. Steel Rule Die Punching 197
29. Production of Meat Trays 200
30. Multilayer Films for Thermoforming Applications 208
31. PET in Thermoforming Applications 211
32. Thermoformed Packaging Made of PLA 227
33. Peel and Reseal 232
34. Foam Packaging with PP and PS 250
35. Blister Packaging of Syringes 257
36. The Production of Drinking Cups 264
37. Ultrasonic Sealing and Cutting in Thermoforming 287
38. Understanding the Brittle Behavior of Polystyrene Cups 293
39. Preprinted Film for Lid Thermoforming 308
Contents ix
40. Flexible Films 311
41. Simulation 316
42. Recycling 324
Glossary 328
Index 329
Preface
T
his book focuses on practical applications. It deals with technical parts, but also
with packaging (the topics range from bathtubs to syringe blisters). Beside the
applications, the respective machine and tooling technologies, automation, and, of
course, semifi nished products and materials are described. Also a large part of the
book is dedicated describing innovations in materials, so that the book can serve as
a useful reference work on raw materials and semifi nished products. Also discussed
are multilayer structures, which are fi nding increasing use for fuel tanks as well as
cheese packaging. Reliable applications of machine, tooling, and materials are dem-
onstrated. The basic principles of extrusion, which are important for thermoforming
are named for clarity ’ s sake without going into depth.
The basic principles of thermoforming and thermoplastics are covered briefl y,
as there are already several standard works dealing with these subjects. The present
book is intended to complement, not replace the existing literature on thermoform-
ing, and to open up new perspectives on the applications considered within. The
author is grateful to all those writers who have advanced, described, and explained
thermoforming and made it popular.
The aim of the book is to communicate points worth knowing about thermo-
forming and to arouse interest. The author hopes this book will show the reader the
diversity and sophistication of the thermoforming industry and ways of implement-
ing cost - effective production.
S ven E ngelmann
xi
1
Chapter
Introduction
R
eference books can be diffi cult to read and understand. Often technical connec-
tions and contexts are described by using a lot of mathematics — and often right from
the beginning — so that a large part of the target group is overcharged or quickly
loses interest. However, reading books on technology and engineering can be fun.
Books dealing with technology should impart knowledge at an adequate pace. We
live in a world that is dependent on a multitude of technologies. Yet it can be
observed that fewer and fewer young people are interested in technical professions.
What are the reasons for this development? It is true that the rush of today ’ s technol-
ogy can initially have a discouraging effect. A lot of technology has become so
complex and abstract that it is no longer possible to understand the connections
through mere refl ection or observation. As the modifi cations to technologies and
processes come even faster, is it possible to keep up with these developments? The
answer is yes!
There will always be technological development because economic issues and
ecology are driving forces. Technological advancements, however, depend on the
degree to which enthusiasm for technology can be aroused in persons with a certain
talent and a disposition toward engineering. To some extent this book is based on a
series of lectures called the “ Basics of Thermoforming. ” Among these lectures the
discussions range over many topics, even to the “ mere ” production of a yogurt cup.
There are many people who are not directly involved in the development of
technologies but who exert nonetheless an infl uence on technological developments.
These decision makers, however, do depend on basic knowledge of the technological
linkages and contexts.
This book is intended as a reference book for the relatively small industrial
sector of thermoforming applications. This book focuses on thermoformed products
and applications. All of us once had the experience of asking ourselves, when con-
templating a formed part, how was this part produced? This book is subdivided into
the description of technical formed parts and of packaging.
Some parts may not even look like thermoformed parts to the casual observer.
This book will discuss the enormous possibilities of thermoforming at a level that
Advanced Thermoforming: Methods, Machines and Materials, Applications and Automation,
First Edition. Sven Engelmann.
© 2012 John Wiley & Sons, Inc. Published 2012 by John Wiley & Sons, Inc.
1