(Munich, May 27th 2015) The Fuayo Group, the largest Chinese manufacturer of glass for the automotive industry, has relied on technologies from the KraussMaffei Reaction Process Machinery Segment for polyurethane encapsulation of its automotive glazing right from the very beginning. The Fuayo Group and KraussMaffei started their cooperation in 2002. Since then 19 RimStar mixing and metering machines with a total of around 50 mixing heads for polyurethane processing have been used successfully at six plants of Fuyao. In 2014 KraussMaffei again delivered five RimStar systems with a further nine mixing heads to China and another system with two mixing heads as the first of several machines to the Fuyao plant in Lake Orion, MI, USA.
On its home market of China Fuyao is already the market leader for automotive glass. Founded in 1987, the company is also one of the world's largest suppliers in this segment. Its customers include the largest internationally operating manufacturers of automobiles and buses, for example VW, General Motors and Ford. In order to encapsulate automotive glazing, Fuyao has exclusively used the sophisticated polyurethane mixing and metering technology from KraussMaffei from the start. Thomas Elfroth, Technology Manager for Window Encapsulation and responsible for Asian markets, explains why: "Although the RIM windows encapsulation process is the most expensive process compared with other processes, RIM windows encapsulation is now the industry standard on account of the durability of the polyurethane seals, the process reliability and the installation advantages of a polyurethane seal compared with bonded rubber seals or thermoplastic-injected seals." Thanks to their special material properties, polyurethane systems are highly suited for automotive applications. The material is resistant to UV light, is very light and yet resilient, has practically no residual compression and dampens vibrations and sound. Polyurethane systems facilitate large-scale automation and have very short curing times.
Engineered as modular systems, the machines in the RimStar Series can be flexibly configured to match application specifications and customer requirements. Polyurethane materials can be perfectly conditioned, metered and mixed using RimStar machines. The wear-optimized high-pressure pumps in the RimStar Series, which were developed and produced in-house by KraussMaffei, also permit exact and reliable metering of different matrix components. Magnetic couplings, volume or mass flow meters, heat-balancing systems and sophisticated MSR technology are all part of the metering system standard. KraussMaffei offers its customers a large number of variants for optimum availability and heat-balancing of material components. "It does not matter what size of component and what production volume customers want to produce, KraussMaffei has a customized solution for them," said Elfroth.
Mixing heads are the second main component of the RimStar machines. The two normally liquid components of the polyurethane system are mixed in the mixing head. In polyurethane processing one component consists of polyols, catalysts and additives while the second component contains isocyanate. The ideally matched system components in the KraussMaffei technology provide short, rheologically optimized line paths between the individual machine components with the result that only minimal pressure losses occur and the temperature can be controlled precisely. This means that the customer Fuyao can always guarantee the high process reliability and excellent product quality which its automotive customers demand.
The electric mold carriers in the WinCap Series, which were completely revamped in 2013, have been successfully used for many years to encapsulate vehicle glass panes with polyurethane. The improved mold carriers offer machine operators better ergonomics and greater user-friendliness because the swiveling mold fixing platens make it easier to remove mold parts and insert substrates. Parallel mold carrier movements and high traveling speeds enable short cycle times and high productivity. The other main advantages are a reduced noise level and low energy consumption due to the electric drive units. Optionally available magnetic clamping plates also make it easier to perform necessary mold changes. This ensures fast flexible production.
Main point of contact for Fuyao are the employees at KraussMaffei China who always cooperate closely with their colleagues at the KraussMaffei head office in Munich. They guarantee a fast and smooth installation and commissioning of the high-tech products at costumers. Service work is also naturally carried out locally by employees of KraussMaffei China.