Surface Quality Improvements of

Automotive Applications with

RocTool Induction Technology

October 9, 2014 – Peter Wentzel – Cel Kunststoffen - Diepenbeek

 RocTool Company

 Creation of the Company : 2000

 R&D, licensing out of Innovative Molding Processes

 RocTool comes originally from Composite Industry, and has

adapted technology to plastic injection end of 2008

 30 employees focused 100 % « Heat & Cool »

 RocTool owns a unique portfolio of 15 international patents of

Innovative Moulding Technologies

 RocTool is listed on the NYSE Alternext (ALROC)

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 What RocTool offers

Patents & License Agreements

Feasibility Studies, Engineering und FEA

Induction-Generators and Mold Construction Support

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Installation / Support during Trials
 Where we are

RocTool HQ – Bourget du Lac - France PCE - USA

Proplast - Italy RocTool Taiwan RocTool Japan

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 Where we are

IVW Kaiserslautern CETIM France Comdel Innovation USA

RocTool GmbH – SLG Kunststoff GmbH

Proper Tooling USA Heiterheim Germany (2014)

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 Markets

Aerospace Sport and Leisure

Consumer Energy
products

Electronics Cosmetics

Automotive

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 RocTool « Heat and Cool » Induction Technologies

Cage system® 3iTech®

External inductor Internal inductor

Direct heating Undirect heating 7
 Performance & combination

Cage system® 3iTech®

Heating configuration Slightly closed Fully open/close stage

Heating control Before press closing At all time

(possible between cycles)

Power input 50 to 500kW 15 to 500kW

Process combination 2 side heating – same T 1 side / 2 side heating

1 side + silicon core 2 sides – different T
1 side + vaccum bagging Local heating
1 side + silicon core
1 side + vaccum bagging
Moving elements
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 3iTech® – Tool design

3D groove network

PDA - Part design

PDA – Tool design

Inductor with
insulation layer

Cooling Network
PDA – Final Part

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 3iTech® – Injection Cycle

Coil elements

Cooling
channels

Mould temperature

180°C

80°C
Mould Mould Heating Material Pressure Mould / Part Part extraction
closing injection holding
Induction ON cooling

0 10
Time (s)
 3itech® – Main phenomenon

Molding surface
Induced currents
3itech®
Mold in Magnetic steel
Example 1.2343 (H11)
Electrique resistivity ρr:40 µΩ.cm
Relative permeability μr:55
Thermal conductivity k:27W/m.K

Insulating layers (1 or 2)
Thermal diffusion
Inductor (copper)

Magnetic fields
- No limitation with the length
- No limitation with the shape
Injected currents - No limitation with the power
10kHz – 50kHz

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 3itech® – Heat and cool cycle
3itech®
Information – 3itech®:

• Possibility to supply a high level of power

• High temperature easy to reach: 400°C or more
• Quick cycle time, ideal for large production
• No tool preheating needed
• Process out of autoclave
• Possibility to heat mold open or closed
• Precise control of the energy: general or localized heating area

We control:
• Heating time
• Holding time
• Final heating temperature
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• Final cooling temperature
 Performance Benchmark

Heating speed Temperature Energy cost Process perfomance

Induction Heating up to 25°C/sec up to 400°C Extended

Low to medium

Flow processes* up to 10°C/sec up to 140°C Limited

(Steam; Pressurized water)
Medium high

Electric heater* up to 5°C/sec up to 300°C Limited

Very high

MATERIAL AND DESIGN (2010) 382–395

Research of thermal response simulation and mold structure optimization for rapid heat cycle molding processes, 13
respectively, with steam heating and electric heating - Guilong Wang, Guoqun Zhao , Huiping Li, Yanjin Guan
 An overall control of the process

Electromagnetic analysis Thermal analysis

Flow analysis
Thermomechanical analysis
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Process synoptic

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 Process improvement

- Generator without capacitor box

- Dual configuration (one generator/two circuits)
- Standard interface (CS/ 3iTech; Injection/Composite)
- Integrated interface (physical and software integration)
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Most Important Advantages
Examples of Part Improvements based on Trials,
Development Programs and Production of Parts

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 Surface Quality

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Elimination of visible Weld lines

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 Reduction of Defects

2 Sink Mark Reduction or Elimination dependent on Part configuration and Wall Thickness

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 Surface Quality

TP rich surfaces for Injection with Fibers and Compression of TP Composites

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 Surface Quality

Improved Reproduction of high/low gloss Mold Surfaces

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 Surface Quality

Combination of high and low gloss surfaces

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 Surface Quality

3D Structure Laser Technology Surfaces

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 Surface Quality

IML Technology Surfaces

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Improved reproduction surface Quality
Improved Connection between Film and Part
Less Part Deformation

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 Surface Quality

Improved Flow length / Viscosity and Wall Thickness Reduction

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 Application Examples – part 1

Interior Automotive
Automotive

BMW 1 Serie – Air Vents Trim Audi A8 – Centrale Console

Peugeot 208 – Decoration Trim and Air vents BMW 3 Serie – Air Vents Trim
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 Application Examples – part 1

Electronics
Electronics

Electronic Accessories Electronic devices

LapTop A and D covers Smartphones Battery covers and Body parts

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Special Thanks to CEL Kunststoffen

Thank you for your attention !

RocTool produces parts at Fakuma
Freidrichshafen 14-18 October 2014
Engel Stand A5/5204