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Using P(Pressure)-T(Temperature) Path to Control the Foaming Cell Sizes in Microcellular Injection Molding Process.

Shia-Chung Chen1,2, Che-Wei Chang1,2, Chia-Yen Tseng1

  • 1R&D Center for Smart Manufacturing, Chung Yuan Christian University, Taoyuan 32023, Taiwan.

Polymers
|July 2, 2021
PubMed
Summary

This study enhances microcellular injection molding (MuCell) by controlling foaming cell size using a P-T path. This green molding solution improves polystyrene and thermoplastic polyurethane properties, reducing defects.

Keywords:
dynamic molding temperaturegas counter-pressuregas holding/release timemicrocellular injection molding

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Area of Science:

  • Materials Science and Engineering
  • Polymer Processing
  • Sustainable Manufacturing

Background:

  • Microcellular injection molding (MuCell) with supercritical fluid (SCF) offers green benefits like weight reduction and energy savings.
  • Challenges in MuCell include surface defects (sliver flow marks) and inconsistent mechanical properties due to uneven cell structures.
  • Previous research indicated gas counter-pressure and dynamic temperature control improve product quality in MuCell.

Purpose of the Study:

  • To extend the P-T path concept for enhanced control over foaming cell size and distribution in MuCell.
  • To investigate the impact of additional parameters like gas pressure holding/release time and mold cooling speed.
  • To demonstrate improved product quality and uniformity in microcellular injection molding.

Main Methods:

  • Developed a P(pressure)-T(temperature) path strategy within the SCF PT diagram.
  • Incorporated parameters: gas pressure holding time, release time, and mold cooling speed.
  • Applied the P-T path method to microcellular injection molding of polystyrene (PS) and thermoplastic polyurethanes (TPU).

Main Results:

  • Successfully controlled foaming cell size and achieved uniform size distribution in MuCell of polystyrene.
  • Demonstrated promising results in preliminary studies with elastomer thermoplastic polyurethanes (TPU).
  • Indicated the P-T path approach effectively mitigates defects associated with uneven foaming.

Conclusions:

  • The P-T path strategy offers precise control over cell morphology in microcellular injection molding.
  • This advanced process control leads to improved surface quality and mechanical property stability.
  • The method shows potential for broader application in green molding solutions for various polymers.