Lightweighting Techniques for Thermoplastic Polymers
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1 Lightweighting Techniques for Thermoplastic Polymers by Maria Rosa Contardi, Maria Teresa Scrivani K12 Midterm conference, May 18 th 2017
2 Mission Proplast private R&D centre, representing the «actors» of polymer and composite materials and processing industry To know more about partner companies see:
3 Our Premises
4 Technical training Our activities
5 EU collaborative research projects Improvement of the plastic packaging waste chain from a circular economy approach (H2020) Developing Novel Fire-Resistant High Performance Composites (FP7) Development of biophotonic device based on flexible light emitting textile dedicated to the monitoring and treatment for dermatologic diseases and carcinoma (FP7) Innovative sensor-based processing technology of nanostructured multifunctional hybrids and composites (FP6) Innovative process and solutions to reduce the weight of PET containers and boost the diffusion of the green (Life+)
6 National collaborative research projects GreenFactory4Compo Green Factory for Composites (Regione Piemonte - Piattaforma «Smart Manufacturing») Veicoli urbani stradali su gomma ecologici, ergonomici, economici, sicuri ed interconnessi, per il trasporto di persone e/o merci (Ministero per lo sviluppo economico Bando «Industria 2015») Sistemi e Componenti per il recupero dell energia e l efficienza energetica di autoveicoli (Regione Piemonte - Bando «Piattaforma Automotive») DIATEME POLILED WIN-STREET FILGREEN 3D Filter Dispositivi ad alto contenuto tecnologico per il settore biomedicale (progetto PON, Ricerca e Competitività Regioni Convergenza) Materiali polimerici per LED ad alta efficienza (Regione Piemonte - Bando «Poli Innovazione») Water IN: STReet design with Environmental Engineering Technologies (for urbanized areas) (Regione Piemonte - Bando «Poli Innovazione») Studio di fattibilità di FILati a base GRafenE per l immagazzinamento di Energia (Regione Piemonte - Bando «Poli Innovazione») Stampa 3D per miglioramento di membrane per filtrazione di gas Regione Piemonte - Bando «Poli Innovazione»)
7 Training activities Classes for graduated students - post University specialization degree in Polymer Science and Technology Classes for high school graduates - injection molding - mold maintenance - CAD for plastics Classes for people working in the plastics sector - more than 30 different theoretical and practical classes on plastics materials and processing technologies held every year - training courses designed upon specific company needs
8 Dissemination activities Seminars and conferences about new materials and new technologies Events examples: Heat & Cool Technologies Conductive Polymers Technical conference on Mucell technology Energy management for the plastic processing industry Polymers compounding Scientific moulding Fiber reinforced composites
9 Materials engineering Tailoring of formulations vs. the final application by the means of different technologies (compounding, melt blending, reactor and solid state polymerisation) Explorative and feasibility studies about new polymers and additives Environmental sustainability: biopolymers polymers for green applications (photovoltaics, membranes) recycling of post-consumer waste Development of high-performance polymeric materials: flame retardant materials nanocomposites high stability polymers (vs. aging, weathering, stress cracking) metal replacement thermoplastic polymers adhesive polymers food packaging materials conductive plastics
10 Injection molding (Heat-and-cool, Roctool, Mucell ) Pre-series molding Compounding Film extrusion Thermoforming Thermoplastics & thermosets composites Metal/ceramic injection molding (MIM, CIM) Process engineering
11 Product engineering Product and process engineering FEM structural simulations Process simulations Development and optimization of new products Design and manufacturing of pilot molds Rapid prototyping Static/dynamic non linear analysis Impact analysis Modal/vibrations analysis Thermoplastics injection molding simulations Thermosetting injection molding simulations Blow molding/thermoforming simulations Thermal analysis
12 Lightweighting in injection molding: the MuCell technology The two key elements of MuCell technology: 1. Lowering of the viscosity of thermoplastic resins by controlled feeding of gas (either N 2 or CO 2 ) into the melt 2. Creation of a microcellular structure in the part core by gas expansion in the cavity Proplast demo line Installed on Engel injection machine tons, 55 mm screw grams typical part size CO 2 or nitrogen
13 Lightweighting in injection molding: the MuCell technology A single phase solution is created by injecting the SCF (super critical fluid) into the thermoplastic melt during screw recovering
14 Lightweighting in injection molding: the MuCell technology MuCell line typical layout
15 Lightweighting in injection molding: the MuCell technology Typical sandwich structure of MuCell parts: Compact skin - Foamed core - Compact skin
16 Lightweighting in injection molding: the MuCell technology Foaming occurs during injection into the mold Time Time Low pressure in the mold cause SCF to form cells Cells grow until the material freezes or the mold cavity is full
17 Lightweighting in injection molding: the MuCell Process MuCell benefits Cavity foaming process instead of post pressure lower clamping force Without MuCell Injection unit lower viscosity, leading to better filling behavior and lower pressures better filling behavior new part design and gate positioning possible potential temperature decrease Part integral structure lower part weight less warpage no sinkmarks MuCell MuCell + Heat & Cool
18 Productivity improvement: overall cycle time reduction Lightweighting in injection molding: the MuCell Process
19 Lightweighting in injection molding: the MuCell Process Productivity improvement: reduction of hydraulic pressure Solid MuCell Peak p c = 1045 bar Peak p c = 448 bar Screw position Data Com Connector, PBT 30 % GF 57 % reduction in peak cavity pressure Due to viscosity reduction, less resin volume, no pack & hold pressure Longer tool life
20 Lightweighting in injection molding: the MuCell Process Case History #1 : Cam Cover Achieved benefits: 30% reduced machine size (350 instead of 500 ton for conventional molding) Improved cycle times, allowing for simultaneous production and assembly process Lighter part Improved flatness
21 Lightweighting in injection molding: the MuCell Process Case History #2 : Dual fan shroud Achieved benefits Typical weight reduction 7-10% Machine size reduction from 1000 tons to 500 tons Cycle time savings of 25-40% 200% improvement in fatigue resistance Cpk values improved by 50%
22 Processing: injection molding - RocTool Roctool Processes Advanced Heat & Cool technology for Composite and Plastic Injection molding by using electromagnetic induction allows to heat a mould in a matter of seconds. Roctool benefits Optimal surface quality: glossy or mat, no visible weld lines Thickness reduction is possible Mechanical properties increased Pressure reduction High temperature molding is possible Very fast heating of the mold
23 Processing: light weight extrusion - Promix Promix Solutions In extrusion processes temperature differences in the melt are generated by the plasticizing process in the screw, melt pumps, screen changers and even by empty pipe sections. Melt Blenders such as Promix blenders efficiently equalize temperature variations over the whole cross section. Equal melt temperature and velocity are key for high quality extruded products
24 In an empty pipe polymer melts will form a laminar profile Promix melt blenders destroy the laminar profile and create a very effective cross mixing resulting in: Equal velocity Equal temperature Narrow residence time distribution Excellent melt homogeneity Processing: light weight extrusion - Promix
25 Processing: light weight extrusion - Promix
26 Processing: light weight extrusion - Promix Effective temperature homogenization
27 Benefits of Promix Mixing Nozzles Processing: light weight extrusion - Promix Effective avoidance of color streaks Equalized color depth / better color appearance Saving of 20 30% master batch (= to > Euro savings / year) No brilliant spots due to homogenization of temperature profile Reduced cycle time due to optimized processing parameters Better tolerances Improved processing of recyclates (usability of more recyclate or better product quality) Improved balancing of hot runner systems shot 1 shot 2 shot 3 shot shots of non colored PP can purge out theblue masterbatch
28 Processing: light weight extrusion - Promix Promix foaming system is a patented process for the production of extruded microcellular foams. Main features: Significant weight and cost reductions High quality microcellular foams Density reductions of 10 to >70% Use of the environmental friendly blowing fluids CO2 und N2 No licenses
29 Processing: light weight extrusion - Promix Promix foam system with fluid injection and static mixing and cooling modules Promix foam extrusion systems are installed downstream of the existing extruder barrel and consist of components for fluid injection, homogenization and cooling. The blowing fluid is provided by a high precision gas dosing station.
30 Processing: light weight extrusion - Promix Advantages of physical vs. chemical foaming: Fast amortization of investment, usually < 1 year Higher process stability, better cell structure Lower foam densities possible No health risks due to chemical residues Production waste is 100% recyclable Improved cell structure and smoother surface in foam extrusion, thanks to mixers
31 Processing: light weight extrusion - Promix Installation example
32 Case History #1 : dairy products packaging Processing: light weight extrusion - Promix
33 Processing: light weight extrusion - Promix Case History #2 : PP foam core pipes PP foam sheet Automotive application Density 210kg/m3 (13lb/ft3) Result: Reduction of foam density
34 Thanks for your attention Proplast - Consorzio per la promozione della cultura plastica Strada Savonesa, Rivalta Scrivia AL Tel: proplast@proplast.it Form
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