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Gas-and-Water-Injection-Technology

Gas-and-Water-Injection-Technology
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Gas-and-Water-Injection-Technology

Product catalog summary
Introduction
The document explores advanced gas and water-assisted molding technologies, emphasizing gas injection technology for producing high-quality, low-stress plastic components. These technologies are advantageous for manufacturing thick-walled components such as car mirrors and door handles, and for reducing cooling times in automotive cooling lines.
Applications
These technologies are applicable across various sectors, including automotive, home and garden, consumer electronics, medical, packaging, and construction. Specific applications include car exterior parts, kitchen appliances, medical equipment, packaging materials, and construction components.
Assisted Molding Technologies
Assisted Injection Molding (AIM) involves injecting gas or water at high pressure into plastic molds to create hollow sections, reducing weight and cycle time. The document details the short shot and full shot processes, highlighting the importance of precise gas injection to prevent defects.
System Technology
This section outlines the equipment and processes for gas and water-assisted molding, including the use of compressor stations and control modules for pressure generation and regulation. It distinguishes between discontinuous and continuous gas pressure generation.
Compressor Stations
Compressor stations are designed for compressing nitrogen or carbon dioxide for gas-assisted molding. The document provides technical specifications for different compressor models, focusing on their mobility, efficiency, and compatibility with various gas supplies.
Control Modules
Control modules regulate the injection pressure in gas-assisted molding processes. Equipped with proportional valves for precise pressure control, they can be adapted to different injection molding machines. The document details the technical specifications and functionalities of various control module models.
Water Assisted System
The water-assisted system integrates pressure generation and control in one unit, optimizing the molding process for components requiring internal and external cooling.
Gasdosing Station and Gas Injectors
The gasdosing station and injectors are crucial for precise gas delivery in the molding process, ensuring consistent quality and efficiency.
Service and Additional Products
The document concludes with information on service offerings and additional products related to gas and water-assisted molding technologies.
Overview
This document provides detailed technical specifications and applications for various Maximator systems used in gas and water-assisted injection molding processes. It covers compressor control modules, water-assisted systems, gas dosing stations, and hydraulic units.
Compressor Control Modules
The RM350 and RM500 series are designed for gas-assisted injection molding, utilizing nitrogen or carbon dioxide. These modules include features like high-pressure gas boosters, proportional control technology, and visual pressure/time profile representation. They are compatible with all injection molding machines and offer high repeat accuracy.
Water Assisted System
The MAXIMATOR Water Assisted System is used for molding applications with water, offering significant cycle time reductions due to water's higher cooling effect compared to gas. It includes volume-flow and pressure control, with features like a touch panel for monitoring and a compact design for easy handling.
Gas Dosing Station
The DSD 500 Gas Dosing Station is used for high-pressure gas dosing in physical foaming processes. It features a mass-flow regulation concept that adapts to pressure variations, ensuring a consistent microcellular foam structure. The system is designed for low raw material consumption and offers good process stability.
Gas Injectors and Control
Gas injectors control the flow of nitrogen into molds, featuring self-cleaning functions and high reproducibility. The Gas Injection Control (GIC) module monitors gas consumption and detects mold leakages, aiding in cost reduction and process monitoring.
Hydraulic Units
The MAXIMATOR-HAG hydraulic unit supplies hydraulic power for driving mechanisms and actuating cores in molds. It supports up to 6 double-acting cylinders and is compatible with all injection molding machines, offering reliable operation through PLC control.
Technical Specifications
The document includes detailed technical data for each system, such as pressure ranges, flow capacities, and dimensions, ensuring users can select the appropriate system for their specific application needs.
Specifications
The mobile core control is designed for injection molding machines lacking core control. It features adjustable hydraulic pressure (20-210 bar), Siemens PLC 7 control unit, and various connection specifications. The unit is compact and easy to install.
Service and Support
Maximator offers global support with over 50 specialists providing technical and engineering expertise. Services include operational startup, training, maintenance, and supply of original spare parts. Maintenance agreements ensure regular system upkeep.
Design and Consultancy
Experts provide consultancy on gas-assisted molding, offering CAE analyses and mold trials. Comprehensive training is available for factory technicians, maintenance engineers, design engineers, and salespeople.
Additional Products
The company offers a range of hydraulic and pneumatic systems, high-pressure technology, and testing equipment. This includes compact hydraulic units, gas booster stations, valves, fittings, and tubings, with a focus on high-pressure applications.
High-Pressure Equipment
Maximator provides oil-free gas boosters and pumps, suitable for explosion-protected areas, and high-pressure testing and production systems, including autofrettage machines and pressure pulse test machines.
Industry Applications
Maximator's products are used in automotive, chemical, mechanical engineering, energy, oil, and gas industries. The company emphasizes reliable systems for gas and water pressure generation and control.
Contact Information
Maximator GmbH is headquartered in Nordhausen, Germany, with detailed contact information available on their website.
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Catalog excerpts

Gas-and-Water-Injection-Technology-1

MAXI MATO R Maximum Pressure. High Pressure Technology • Testing Equipment Hydraulics • Pneumatics MAXIMATOR Maximum Pressure.

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Gas-and-Water-Injection-Technology-2

Content Content: Page: Introduction Applications 3 Assisted Molding Technologies 4 System Technology 5 Compressor Stations N2 / CO2 6 – 7 Control Modules N2 / CO2 8 – 11 Compressor Control Modules N2 / CO2 Water Assisted System Gasdosing Station External Hydraulic Power Pack HAG Additional Products How does plastic keep its perfect shape? How do your cycle times stay ahead of the market? How can instant coffee be a real pleasure? » With High Pressure. » With High Pressure. » With High Pressure. Do what you want with your injection molded parts: with the pioneering gas injection technology of...

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Gas-and-Water-Injection-Technology-3

Exterior Wing Mirrors Side panels Door handles Lighting Bumpers Radiator grills Roof rails Foot plates Motorcycle rear grab bars Interior ■ Overhead grab handles ■ Door handles & pockets ■ Instrument panels ■ Clutch pedals ■ ‘A' and 'B' pillars ■ Glove boxes ■ Seating components ■ Rear parcel shelves ■ Sat Nav facia ■ Air bag covers Under Bonnet ■ Air intake manifold covers ■ Engine cover and trays ■ Battery lids Rail and Air Transport ■ Seatback tables ■ Luggage area panels ■ Oxygen mask panels ■ Flat screen TV panel surround ■ Flat screen TV back panel and base ■ Hi-Fi and car stereo facia...

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Gas-and-Water-Injection-Technology-4

Assisted Molding Technologies Assisted injection molding technologies Assisted Injection Molding (AIM) is part of a family of technologies that are operated with plastics processing methods to improve product quality and significantly reduce cost. The technologies include the injection of gas or water at high pressure into plastic in an injection mold. This cores out sections of the part, leaving hollow areas which lower part weight and cycle time. The short shot process Gas injection PGas Plastic core Melt injection Injection phase • 70% ± 20% of the volume of the cavity is dosed and injected...

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Gas-and-Water-Injection-Technology-5

 System Technology Systems technology of gas and water assisted molding technology For the application of gas and water assisted injection technology, as well as the injection molding machine, basically two additional functions are to be applied: Pressure generation and pressure control. In the area of gas assisted molding technology, two different types of gas pressure generation are differentiated. On the one hand, discontinuous gas pressure generation which is mainly employed for the GIT process in case of individual machines and, on the other hand, continuous gas pressure generation which...

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Gas-and-Water-Injection-Technology-6

Maximator Compressor Stations are specially designed for the compression of nitrogen or carbon dioxide from gas bottles, and are employed for pressure generation in gas assisted molding applications. VP/120/500/300/N2 Compressor station for nitrogen to 415 bar The VP/120/500/300/N2 compressor station is designed for the effective compression of nitrogen. The nitrogen supply can be implemented both via nitrogen bottles (200 bar and 300 bar) or a liquid nitrogen storage (20 bar - 30 bar). • Compressor with continuous pressure generation • Mobile • Bottle pressure is used optimally • Oil-free and...

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Gas-and-Water-Injection-Technology-7

The gas booster supplies continuously into a storage tank and thus guarantees that the pressure in this storage tank is always within the adjustable limit values. The required gas volume of the connected control modules is made available from this storage tank. VP/500/CO2 Compressor station for liquid carbon dioxide to 415 bar The VP/500/CO2 compressor station is designed for the effective compression of carbon dioxide for the new CO2 GIT process. The carbon dioxide supply is implemented with CO2 riser pipe bottles or riser pipe bundles. • Special CO2 Gas Booster • Optimized cross sections for...

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Gas-and-Water-Injection-Technology-8

Maximator Control Modules are suitable for series production with high-pressure nitrogen supply or high-pressure carbon dioxide supply, at a pressure of 500 bar (7,250 psi). The control modules regulate the injection pressure in the GID process. RM/500/2(4)/N2 Control Module for nitrogen up to 500 bar The RM/500/2(4)/N2 Control Module is designed for the exact injection of nitrogen in gas assisted molding processes. Depending on the design, the Control Module is equipped either with 2 or 4 highly-dynamic, Maximator 3/3-way proportional valves for the pressure control, and can optionally supply...

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Gas-and-Water-Injection-Technology-9

proportional valves from Maximator. As a result, both switchover markings and melt standstills are effectively avoided. Thanks to the intelligent software, production parameters can be flexibly adapted to individual requirements. With this, rising as well as falling ramps can be freely adjusted with up to 10 individual pressure levels. This guarantees perfect interior surface quality in the gas chanel. RM/500/2(4)/CO2 Control Module for liquid carbon dioxide up to 500 bar The RM/500/2(4)/CO2 Control Module is designed for the exact injection of carbon dioxide in the new CO2 GIT process. Depending...

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Gas-and-Water-Injection-Technology-10

The MAXIMATOR RM350 Series Control Modules are precision Gas Controllers for Assisted Injection Molding up to 350 bar. The Control Modules are equipped with 2 or 4 gas control valves. Two interfaces allow the RM 500 Series Gas Control Modules to work with 1 or 2 injection molding machines at the same time. RM350 Series Control Module for Nitrogen up to 350 bar, equipped with a gas booster and core control packs as an option. The Control Modules of the RM350 Series are designed for the precise injection of nitrogen for Assisted Injection Molding processes up to 350 bar. Because of the modular...

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Gas-and-Water-Injection-Technology-11

MJiXIIVIATOFt Maximum Prossuxo, No Core Controls; |P»Q Core control signals with interface for external hydraulic power pack /*Q Internal hydraulic power packfor MInte rnal hydraulic power pack for o peration of 4 cores Technical Data Connections Air inlet (B1 only) G1/2 Quick release pairs G1/4 Single phase 110v/220v 50/60Hz Power cable provided 220v-575v 3 phase, 50/60 Hz. Cable gland provided, power cable by customer.

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.