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The Pernoud Group presents its Multitube (Molding) Innovation

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Multitube Innovation

• Mold bonding areas, both chemical and mechanical, that allow the assembly of multiple components within the mold in order to produce a complete finished part

• Available for applications using standard (single barrel) or multi-material injection molding machines utilizing multiple barrels

• Components are transferred within the mold by EOAT or rotary plate

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Multitube Innovation - Case study 1

The sample part shown is an example of Multitube technology•  Product :

• Air Intake Manifold

•  Operations performed:• Cover overmolded by Multitube technology (transfer by EOAT)• Overmolding of 4 metal inserts to assemble the plate (placed by EOAT)• Overmolding of a gasket in TPE resin to seal the connection plate

(by an additional injection unit attached to mold, E-multi from MoldMasters)

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Multitube Innovation - Case study 1

Overmolding of a gasket

Progress of Development…

MULTITUBE Concept

• Multiple components are joined within the mold with molded bonding areas (both chemical and mechanical) that allow the delivery of a finished product each shot.

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Control of Resin Compatibility

PP GF20 + PP GF20PP GF20 + SEBS

PA6.6 GF35 + PA6.6 GF 35PA6.6 GF35 + PPA

Examples of Resin Compatibility:

Tests configuration: water + glycol from 248°F to 320°F

PPS + PPSPA6 + PA6 SOFT

Preliminary Testing of bonding is performed on sampling mold to confirm resin compatibility

InsertOvermolded

Part

Bonding Area

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Validation of Seal between Components

The Multitube seal is obtained by fusion of the part located on the insert.The mechanical strength is done by the recovery of materials.

Validation of the aging parts- In an Oven- Filled by glycol and water

Test Description: Multitube parts are submitted to 36.3 psi pressure at 248°F

Original Part

After 450h Static Pressure

After 450h Dynamic Pressure (in cycle) Inspection: by Micrographic Analysis

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Burst Testing Performance

Test Conditions:• Water pressure increments until failure• Step pressure: 29 psi• Maintaining level: 1 minute

Test nr 1: • Part Temperature: 68°F 24h • Resin: PA 66.6 GF 30 • Water Temperature: 64°F• Failure pressure: 232-261 psi

Test nr 2:

• Part Temperature: -40°F 24h • Resin: PA 66.6 GF 30 • Water Temperature: 41°F• Failure pressure: 232-261 psi

Test nr 3:

• Part Temperature: 284°F 24h

• Resin: PA 66.6 GF 30 • Water Temperature: 176°F• Failure pressure: 160-188 psi

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Multitube Innovation - Case study 2

EXAMPLE: RAMPE K4M ECOTECH, Production Part

Vibration WeldingInitial Design

MULTITUBE Concept

9M

ultit

ube

Proc

ess

FUNCTION of the part: - Circulation of Engine Cooling Fluid

MATERIAL: - PA 6.6 GF35

CONCEPTION: - 2 parts welded by vibration to enable the stripping of complex shapes

PROCESS: 1+1 cav. mold- Injection by sequential valve gating- Parts removed by EOAT- Positioning and set up on the welding unit- Vibration welding- Tightness controlled at 100%- Parts cleaning- Parts packed

FUNCTION of the part: - Circulation of Engine Cooling Fluid

MATERIAL: - PA 6.6 GF35

CONCEPTION: - 2 parts assembly by overmolding in a Multitube mold

PROCESS: 1+1 cav. mold

- Injection by sequential valve gating

- Parts moved and removed by EOAT

- Parts packedTrad

ition

al P

roce

ssMultitube Innovation - Case

study 2

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Cost ComparisonClassic Technology Multitube Concept Cost save / Difference

Resin cost per part 0.957 $ 0.718 $ 25%

Value per part 1.833 $ 1.185 $

Total Value + Resin

2.789 $ 1.903 $ 0.886 $

Global Investments 218,720 $ 211,885 $ 6,835 $

Qty of parts for Payback

- 7,705 parts

Cost save in a full year of production

310,478 $

Cost save after 5 years of production

Basic data for this K4M example:

350,000 parts / year

4.78 $ / kg of PA6.6 GF35

2.789 $ cost per part with classic technology

Press cost: 1,202 $ / day

5 years to produce

1,559,230 $

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Air Duct I4 Ford Transit, 1+1 cav. mold, transfer by EOAT, metal inserts, 420t. press, production in Argentina

Water Duct Fiat Idea + Muse (long version), 2+2 cav. mold, transfer by EOAT, production in France

Water Duct Fiat MDE (short version), 2+2 cav. mold, transfer by EOAT, production in France

Duct RAS – BP Mercedes M230 platform, 1+1 cav. mold, transfer by EOAT, production in France

Multitube Innovation Examples in Mass Production