Bayer MaterialScience AG has installed a fully automatic, robot-aided two-component swivel-plate injection molding machine with 2,300 metric tons clamp tonnage for developing large 3D automotive glazing components at its technical service center in Leverkusen. Injection-compression molding has proven to be the process of choice when it comes to manufacturing parts like panorama roofs in series production, because at reduced injection pressure it delivers low-stress and low-distortion components with excellent surface quality that lend themselves to the application of wetcoats. Further, these automotive glazing applications are well-accepted owing to the weight reduction potential and the new design style.
One special feature of the injection molding machine is that it can be used to produce large components measuring 1.2 m2 using a process known as film insert molding (FIM). Films play a key role in concepts for rear windows made of polycarbonate and in the design of polycarbonate panorama roofs, for example. They enable the implementation of decorative effects and the integration of additional functions. For example, lettering, logos or fade-outs can be applied to the films before the back-injection process. In rear windows made of polycarbonate, films can be used to integrate defrosters for the glazing heating system. Defrosters, for example, could consist of thin heating filaments or conductive, thinly-applied pastes. Similarly, it would also be possible to integrate antennas. It would also be feasible to use films to provide IR sunlight protection for vehicle interiors.
The new injection-compression molding machine is equipped with 17 temperature control units, which enable segmented and close-contour temperature control for the molds and molded parts. The temperature of the swivel platen is controlled separately. It is fitted with ten water feedthroughs for 24 temperature control channels. The new system is designed as a two-component machine to enable, for example, the direct injection of frame components on the glazing unit and the integration of functions such as rear spoilers, light housings and roof rails.
04-Jul-09 
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