Injection molding exhibitor at K 2022

4+4-fold injection molding tool for Luer connector, ©Braunform

Pharmaceutical closure cap Luer-Connector, ©Braunform

At this year's K 2022, the international plastics trade fair from October 19 to 26, 2022 in Düsseldorf, Braunform presents the patented innovation RotaricE²® for compact integration solutions using a tool for a Luer connector (closure cap Pharma).

The RotaricE²® technology is a clever combination of 2-component technology, servo technology, and final assembly of the part in the tightest space. The focus is on reducing costs under the TCO (Total Cost of Ownership) approach while simultaneously increasing production efficiency. With the translational cover closure of caps in the tool, all production factors can be positively influenced. And not only that, Braunform also offers a sustainable tool concept with RotaricE²®, which ensures production through process control rather than quality control. The project was realized together with partners Arburg GmbH & Co. KG, Ewikon Heißekanalsysteme GmbH, Agathon Deutschland GmbH, iQtemp GmbH, Kistler Instrumente GmbH, Meusburger Georg GmbH & Co. KG, Oerlikon Balzers Coating Germany GmbH, and Uddeholm.

Resource-saving and cost-effective. So what exactly does RotaricE²® mean? Specifically, RotaricE²® has led to savings of over 45% in the production process. The technology not only saves time and financial resources but also the use of two injection molding tools and machines, as well as an assembly line for assembling the individual parts, including production space. For example, to realize a cover closure in a multi-component application in just one step within a compact space, Braunform developed a conversion of a rotary movement into a translational movement within a tool. The servo-electrical, rotary drives move quickly, gently, and wearlessly within the mold. This solution is particularly advantageous because it allows an extremely compact radial arrangement of mold cavities with slides or cover closers around a gate or preferably a side gate system. This results in reduced costs and resource consumption while increasing the level of integrated manufacturing in just one tool.

Tool for 2-Component Luer Connector with All-in-One Functions

During the entire trade fair, an example of this tool principle will be on display at the Arburg booth in Hall 13, Stand A13-1 - B13. On an Arburg Allrounder More, the 2K part with small dimensions, a diameter of 10 mm and a length of 11 mm, is produced. The special feature of the tool lies in the combination of the cover closure function and the unscrewing function of the Luer lock thread in a multi-component side gate tool.

The compact design allows a high number of cavities in a small tool size. The 4+4-fold trade fair tool serves as the basis for a compact series tool in modular design, up to 64+64 cavities.

An extraordinary challenge is posed by the small shot weight of the second component: at 0.05 g of the TPE component, the injection unit as well as the hot runner system from Ewikon must be designed with high precision.

Special attention was paid to the modular design during the development of the tool, meaning the modules are individually centered and easily accessible.

Another plus point: the tool's cleanroom-compatible design. Since 2010, the proven Braunform MED Mold® concept stands for the safe use of injection molding tools in cleanrooms. In addition to electric drives and corrosion-resistant steels, a low-fat lubrication using coatings from Oerlikon Balzers and ball centering from Agathon ensure reliable cleanroom operation. Furthermore, diffusion-welded inserts from IQtemp ensure close-to-shape cooling of the thin-sided mold inserts.

On the ejector side, six functions are integrated in the smallest space: these are the core-back function, two slides per cavity, lifting the cover with a lifter, translational cover closing of the closures, unscrewing, and final ejection. The second component is formed using the core-back system, so no part transfer is required. Slides operated by pull/push rods during mold opening eject the snap hooks for the cover. A lifter lifts the cover out of the mold cavity so that the in-mold cover closure of the cap can still be performed within the tool. Finally, the Luer thread is depicted and ejected by a thin unscrewing sleeve. The final demolding of the fully assembled product is carried out via a delicate rod ejector with a wall thickness of 0.60 mm. The four main movements—core-back, lifter, in-mold cover, and unscrewing—are controlled by servo motors from AMK. Ejection is performed via the machine ejector.

Process Control Instead of Quality Control

Process monitoring is carried out using two indirect pressure sensors per cavity, developed by Kistler, which detect defective parts and sort them out via the handling system. For the implementation of the overall project, the hot runner specialist Ewikon equipped the hot side with a Smart-Control system to ensure continuous data analysis and evaluation (real-time data mining). The mold-making partner Meusburger was also involved in the realization of the tool, providing plates and high-quality standard parts.

With the forward-looking tool concept RotaricE²®, the mold-making specialist demonstrates technologically innovative and creative ways to resource-efficient production by integrating multiple production steps into a single tool concept. Braunform's engineers know that in the future, even better and more sensible technology will be needed to produce efficiently and sustainably. The ideal combination of 2K, the use of servo technology, and final component assembly in the tightest space enable new production concepts with lower space requirements and investment volume. Product functions from multiple individual parts can be combined into a single-piece article.