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MAXIMATOR-Gas-and-Water-Injection-

MAXIMATOR-Gas-and-Water-Injection-
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MAXIMATOR-Gas-and-Water-Injection-

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. It highlights benefits such as uniform pressure distribution and reduced cooling times, particularly in automotive and consumer goods applications.
Applications
The technologies are applicable across various sectors, including automotive, home and garden, medical, packaging, construction, and consumer electronics. Specific applications include car parts, kitchen appliances, medical equipment, and packaging solutions.
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, emphasizing the importance of precise gas injection to avoid defects.
System Technology
This section describes the infrastructure required for gas and water-assisted molding, including pressure generation and control. It differentiates between discontinuous and continuous gas pressure generation, with Maximator offering solutions for both.
Compressor Stations
Compressor stations are designed for compressing nitrogen or carbon dioxide for gas-assisted molding. The document provides technical specifications for different models, highlighting features like oil-free compression and mobile design.
Control Modules
Control modules regulate injection pressure in gas-assisted molding processes. They are equipped with proportional valves for precise control and can be adapted to various injection molding machines. The document outlines technical data and compatibility features.
Water Assisted System
The water-assisted system integrates pressure generation and control, offering efficient cooling and reduced cycle times. It is particularly beneficial for applications requiring rapid cooling from both inside and outside.
Gas Dosing Station and Gas Injectors
These components are crucial for precise gas dosing and injection, ensuring optimal consistency and quality in molded parts.
Service and Additional Products
The document concludes with a section on service offerings and additional products available to support the implementation of gas and water-assisted molding technologies.
Core Signals and Hydraulic Power Packs
Core signals offer additional control system hardware with a 32-way interface for external hydraulic power packs. Hydraulic power packs include a 3-phase electric induction motor, gear pump, oil tank, pressure gauge, bypass valve, and changeover valves for cores.
Compressor Control Modules
Designed for mold trials and smaller production runs using gas-assisted injection molding, these modules compress nitrogen to 500 bar, featuring high repeat accuracy and programmable pressure/time profiles.
Water Assisted System (WIT)
Utilizes water instead of gas for injection molding, offering significant cooling effects and reduced cycle times. It features volume-flow and pressure control, with a touch panel for monitoring and process data input.
Gas Dosing Station
The DSD 500 station compresses gas for physical foaming processes, ensuring uniform dosing even with back-pressure fluctuations. It features precise injection flow regulation, reducing production fluctuations and propellant costs.
Gas Injectors and Control
Gas injectors feature self-cleaning functions and high reproducibility, with service kits available for maintenance. The Gas Injection Control module monitors gas consumption and detects mold leakages.
External Hydraulic Unit
The MAXIMATOR-HAG hydraulic unit supplies hydraulic driving mechanisms and controls up to 6 double-acting cylinders or cores, compatible with all injection molding machines.
Mobile Core Control
Designed for injection molding machines lacking core control, it is easy to install and operate, allowing for the movement of units like injectors or hydraulic shutters.
Service and Support
Maximator offers extensive support for gas and water injection systems, including operational startup, training, maintenance, and supply of original spare parts.
Design Consultancy and Tooling
Experts provide consultancy on gas-assisted molding, from concept to production, including CAE plastic and gas flow analyses.
Additional Products
Maximator offers a range of hydraulic and pneumatic systems, high-pressure technology, and testing equipment, focusing on high-pressure applications up to 25,000 bar.
Testing and Production Systems
The company provides advanced testing and production systems, such as autofrettage machines, leakage and burst pressure testing technology, and high-pressure forming machines.
Oil and Gas Equipment
Maximator supplies compact liquid and gas power packs, central feed and circulation systems, and high-pressure test equipment for the oil and gas industry.
Company Profile
Maximator GmbH, headquartered in Nordhausen, Germany, has been a leader in high-pressure and testing technology for over five decades, collaborating with international partners to provide innovative solutions.
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Catalog excerpts

MAXIMATOR-Gas-and-Water-Injection--1

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

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MAXIMATOR-Gas-and-Water-Injection--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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MAXIMATOR-Gas-and-Water-Injection--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...

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MAXIMATOR-Gas-and-Water-Injection--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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MAXIMATOR-Gas-and-Water-Injection--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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MAXIMATOR-Gas-and-Water-Injection--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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MAXIMATOR-Gas-and-Water-Injection--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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MAXIMATOR-Gas-and-Water-Injection--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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MAXIMATOR-Gas-and-Water-Injection--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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MAXIMATOR-Gas-and-Water-Injection--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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MAXIMATOR-Gas-and-Water-Injection--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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