NEWS 
For further editorial information or
electronic files contact: ThermoFlex LLC
Rol Kracoe – Kracoe Szykula & Townsend,
Inc.
PH 248-641-7500 – FAX 248-641-4779
Email: rkracoe@ksthip.com Ph: 931.815.9500 FX:
931.815.9530
E-mail: gregh@thermoflexllc.com
www.thermoflexllc.com
That’s a greater return on investment. PFX-104 Tray & Insert
1st Draft: 2.19.08
Process Application News — For Immediate Release
SYNCHRONICITY
Two processes, two materials...and the collaborative resources of two
thermoplastic forming firms combine to formulate one new dunnage concept
protecting parts, budgets and productivity.
During the past few decades, the
development and proliferation of plastic formulas for tough, high strength
urethanes, polymers, polyethylene and elastomers have revolutionized everyday
products. Also affected are the
packaging those products come in, and even the devices used to handle, convey
and transport those products during their manufacture. Today, manufacturers are relying more and
more on tote boxes, platforms, trays, racking and palletized containers made
from plastics and their numerous derivatives to safeguard parts during handling
and shipping functions.
These new plastic devices are typically reusable yet, unlike
metal containers, usually offer lower initial costs, shorter lead times, are
lighter in weight and require less maintenance costs. Compared to consumable containers such as
cardboard, plastic units eliminate long-term repetitive investments, breakdown
and disposal costs. They are also
impervious to cutting fluids and lubricants, and are better able to protect
parts from collisions. And, within the
alternatives, plastic containers provide economical opportunities to modify
designs to meet a specific application challenge.
Merely substituting a plastic
container for metal or cardboard would make the job simple, according to Greg
Hancock, vice-president and general manager of ThermoFlex LLC, Morrison,
TN-based thermoforming specialists. But,
in most cases, it’s not that easy.
“The number of plastic material
options, the different manufacturing processes, and the applications themselves,”
says Hancock, “present myriad design, engineering and process challenges that
require unique and innovative solutions.
Load capacities, strengths, stacking capability, handling options,
environmental hazards, economics and ergonomics, as well as part configuration
and protection are integral elements of the tool design, the material and the
process selection. Those are the
elements we’ve recently incorporated into a new pallet tray concept designed to
protect heavy metal components.”
In particular, one application Mr.
Hancock refers to was for an automotive supplier who finishes gears and other
drive train components. The supplier had
already switched to vacuum formed trays made from high density polyethylene
(HDPE) for handling in-process gears.
However, there was a problem with the sharp edges of the parts in that,
when placed in the trays, the pieces were gouging the relatively soft tray
surface and creating plastic shavings that could contaminate the parts. This problem was compounded by the fact that
the vacuum forming process does not typically hold tight tolerances, thus parts
could move substantially and make further contact with the surface and create
additional slivers.
That’s when ThermoFlex engineers
proposed a dual faceted solution, combining the economy and size capabilities
of the vacuum forming process to produce trays with the durability and accuracy
of molded thermoplastic urethane (TPU) inserts as nests for the parts. The trays are formed to 1/4" material
thickness, measure approximately 45" x 48" x 3" high and are
designed to hold just one layer of gears—stowing 36 parts in total.
The trays utilize a 180o
stack and nest design that allows the trays to be securely stacked when filled
with parts, then by reorienting the trays 180o to each other,
provides partial nesting to save space for storing and transporting empty
containers.
One unique feature of ThermoFlex’s
new system is working with its sister company, PolyFlex Products (Livonia, MI),
manufacturers of thermoplastic injection, low-pressure foam urethane, cast
solid elastomers and thermoset components, to
create a synergistic approach in developing a single-resource, turnkey
solution. Another feature is using the
TPU material and the injection molding process to fabricate the inserts,
establishing the surface toughness and resilience required to withstand
multiple contacts with sharp edges, and producing ‘nests’ of tighter size
tolerances that restrict movement of the parts.
The inserts are formed to a 1/2" thickness, providing a strong and
stable stowage space.
The molded inserts are attached to
the bottom of the tray by way of an expanding plug or anchor attached to the
insert. The bottom of each tray is
drilled with 36 holes through which the plug end of an insert is pushed...once
through, the anchor expands to prevent its withdrawal and to hold it snugly to
the tray. The interior bottom of the
tray also features a formed projection that each insert fits over to aid in its
positioning.
According to Mr. Hancock, the
two-material, two-process tray and dunnage units are proving to be a success in
many applications in addition to the gear manufacturing project. “The largest parts of these handling systems,
the tray,” he explains, “are made from HDPE, which is about 1/3 the cost of
TPU, just in material. As a result,
we’ve been able to keep the costs contained while improving the performance of
these containers, the quality of the output, and the productivity of the
operations. Working with PolyFlex, with
their range of options and resources, allows us to deliver optimum solutions
instead of promoting just one process or one material.”
ThermoFlex processing capabilities include thermoset cast urethane molding and thermofoam operations in addition to its thermo/vacuum forming capacities to 5' x 9' x 25" deep. Products include urethane coated conveyor rollers, as well as tool protection holders for the metalworking machine industry, assembly tools, bumpers, enclosures, grippers, covers, wipers, seals and custom dunnage components including custom design and prototyping services.
Dual-construction gear handling pallet
trays—using HDPE material and the vacuum forming process for the tray with
injection molded TPU for the inserts are helping to protect parts, eliminate
plastic ‘sliver’ contamination and minimizing costs.