Microcellular Injection Molding Enhancing Design Freedom for Complex
- Slides: 17
Microcellular Injection Molding: Enhancing Design Freedom for Complex Lightweight Plastic Parts Steve Braig, President & CEO Trexel, Inc. Mu. Cell® Injection Molding January 14, 2015
Mu. Cell® INJECTION MOLDING “The most significant plastic processing innovation in the last 20 Years” Mu. Cell Process developed at Massachusetts Institute of Technology. (M. I. T. ) Exclusively licensed to Trexel Inc. in mid 90’s. Trexel over the last 15 years commercialized, industrialized Mu. Cell Technology. Today, Trexel owns over 50 global patents covering article and methods in producing microcellular foam. Support leading OEMs globally from HQ in Boston and through subsidiaries in Japan, Germany, Hong Kong and China. Patented, closed loop processing solution creating predictable and repeatable homogeneous microcellular material structure with average cell size <100 microns.
What is Mu. Cell • Mu. Cell is a foaming technology o Creating a microcellular material structure in thin wall plastic parts • Primarily using nitrogen as the foaming agent o Introduction of N or CO 2 in supercritical state into polymer in plasticizing unit of injection molding machine Trexel Confidential Information
Mu. Cell® Commercial Applications Business Equipment Automotive Industrial & Electrical
DESIGNING FOR Mu. Cell® ð Filling from “thin to thick“ Recommended injection with Microcellular Foam Injection in solid (with Mu. Cell® still possible) ð Wall to rib ratio 1: 1 possible Conventional design Microcellular design
CASE STUDY: VIDEO BEZEL Objective: Injection molded Frame for DVD Video Bezel with high dimensional stability, reduced warpage and high gloss Class A surface finish. • OEM: BMW • Production Platform: 7 Series • Tier I: Johnson Controls Europe • Molder: Groupe Plastivaloire, France Case Study Data courtesy of Groupe Plastivaloire
CASE STUDY: VIDEO BEZEL A) Initial Design 2. 8 mm
Warpage Simulation: Design A, Single Part Material: ABS/PC T 85 XF Warpage 3. 5 mm. Not acceptable
Design B, 2 Parts (2 K Molding Process) Aesthetic part : ABS/PC T 85 XF Technical part : ABS/PC T 884 N 20%GF 1. 6 1. 2
Design B, 2 Parts (2 K Molding Process) Warpage 5 mm, Not acceptable
Design C, 1 Part foamed with Mu. Cell® 2. 5 mm Wall Thickness reduced by 10%
Flow Simulation: Design C, 1 Part with Mu. Cell® Pressure is acceptable
Warpage Simulation: Design C, 1 Part with Mu. Cell® Warpage 1. 6 mm is acceptable
Innovative Solution Solving Dimensional and Aesthetic Requirements Surface Finish with Mu. Cell & Variotherm, Hot/Cold Molding Combination of Mu. Cell® + H/C Molding !
Process Description Mu. Cell® + H/C Solid Final part
Summary of Product Development Technology Material Thickness Pressure Warpage Finish Decision Conventionnel ABS/PC 2. 8 mm 23 MPa 3. 5 mm NO GO H/C ABS/PC 20%FV 2. 8 mm 31 MPa 2. 5 mm OK NO GO 2 K ABS/PC + 1. 2 mm ABS/PC 20%FV 1. 6 mm 69 MPa 87 MPa 5. 0 mm OK NO GO Mu. Cell ABS/PC 2. 5 mm 15 MPa 1. 6 mm NO GO Mu. Cell+H/C ABS/PC 2. 5 mm 11 MPa 1. 7 mm OK GO CONCLUSION: Combination Mu. Cell & Hot/Cold Molding as enabling Technology!
THANK YOU! Brent Strawbridge, V. P. Sales North America b. strawbridge@trexel. com, Ph: 717 -940 -8662 Steve Braig, President & CEO s. braig@trexel. com, Ph: 781 -932 -0202
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