INTEGRAL SKIN POLYURETHANE

1
INTEGRAL SKIN POLYURETHANE

• Presented By Onur Karagöz

2
Introduction

• The application of a layer of polyurethane over
  an injection moulded part is a commonly used
  technique in the polyurethane industry.

3
The idea

• Injection mould a thermoplastic part, after
  demoulding, place it in a foaming station and
  inject a flexible integral skin formulation on
  it.
• The different properties of the two plastics
  combines and provides different mechanical and
  functional properties.

4
What is the product?

• A coloured polyurethane seat made with a flexible
  integral skin will be applied over a
  polypropylene injection moulded chair.

5
The Process

• A polypropylene chair is made by injection
  moulding.
• A polyurethane trapezoidal seat was designed over
  the seating surface.
• They have binded without adhesion between PU and
  PP.

6
The Process
The 9 polyurethane buttons that hold the seat in
place.
7
The Machinery
A conventional Cannon A-System 40 metering
machine was used with an FPL 14 mixing head.
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The Machinery

• Injection Moulding Machine Sandretto Mega T SEF
  100

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The Machinery

• Technical Specifications
• Clamping force1500 ton
• Shot weight (max)12306.296 g
• Distance between tie-bars (H)1375 mm
• Distance between tie-bars (V)1375 mm
• Screw diameter155 mm
• Mould height (max)1600 mm
• Mould height (min)450 mm
• Opening stroke (max)1530 mm
• Core pullsYes
• Number of core pulls4 Injection volume11698 cm³
• Injection pressure1520 bar
• Other specifications
• 6 drop sequencial injectionIntegrated 24 zone
  mould heatsRobot Dal Maschio 3E-2800

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Raw Materials

• Specflex NR 473 polyol
• Specflex NE 117 isocyanate

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Feasibility

• a.Specflex NR 473 polyol 1400 per Ton
• b.Specflex NE 117 isocyanate 2300 per Ton
• c.Polypropylene fiber 1570 per Ton.

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Feasibility

• Black Integral Skin
• 360 Parts/Day 260 /day

• Polypropylene Chair
• 1440 Parts/Day 7200 /day

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Feasibility

• 65 raw material, 35 energylabor
• Total Production Cost 11476 /day

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Feasibility

• Factory Building Cost 3000 m2 x 266 798,000
• Machinery Cost Injection Moulding 500,000
• PU Foaming 350,000
• Employees 1 Engineer 2500
• 6 Operators 500 x 6 3000
• 1 Manager 5000
• Total 10500 / month

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Feasibility

• Energy Consumption 120kW/h x 70 x 24 x 8.9 YTL
  17942 YTL 12815 per day.
• There are 2 production lines. 25500 per day.
  307,500 per month.
• General Consumptions 10000 per month.
• Raw Materials
• PU 250 pieces/day 250 x 0,72 180 per
  day 5400 per month
• PP 1000 pieces/day 1000 x 5,02 5020
  per day 150,000 per month

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Feasibility

• Total Expenses (Per Month) 593400
• Unit Price for 1 Chair 10
• 10 - 5,64 4,26 profit per chair.
• If we sell 2000 chairs per day, 720,000 chairs
  per year.
• 720,000 x 4,26 3,067,200 profit for one year.
• Primary Investment 1,650,000
• We double the machinery prices in 1 year. So the
  investment is profitable.

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References

• 1.http//www.thecannongroup.com/immaginigruppo/pap
  ers/Chair_UTAS99.pdf
• 2.http//www.etintelligence.com/etig_root/etknowle
  dgeseries/yarnsfibers/pdf/YarnsandFibersPriceWatch
  ReportHighlights260606.pdf
• 3. http//www.immnet.com/articles?article1242
• 4.http//www.machinepoint.com/machinepoint/invento
  ry.nsf/WEBSECMACHALL_2/C81DC86C848DD2C5C1256F5C004
  395A0?OpenDocument