A new concept for ultrasonic flow enhancement in injection moulding, to eliminate polymer leakage problems

注塑成型中超声波流动增强的新概念，可消除聚合物泄漏问题

基本信息

批准号：
710417
负责人：
金额：
$ 12.74万
依托单位：
THE TECHNOLOGY RESEARCH CENTRE LIMITED
依托单位国家：
英国
项目类别：
GRD Proof of Concept
财政年份：
2013
资助国家：
英国
起止时间：
2013 至无数据
项目状态：
已结题

来源：
https://gtr.ukri.org/projects?ref=710417
关键词：
new concept ultrasonic flow enhancement

项目摘要

TheEU polymer processing industry continues to contract, with companies struggling toremain competitive. Whilst energy cost reductions would be welcomed, cycle time andcomponent thickness are key drivers of financial performance, with parts costed as a functionof cycle time & machine hourly rate.Our idea is to apply ultrasonic energy into the molten polymer just before it enters the cavity.This can yield as much as 60% reduction in melt viscosity, enabling a significant reduction inequivalent melt temperature, thus saving both heating & cooling energy.Our goal is to establish a clear ‘proof of concept’ for a novel transducer/sonotrode/meltchamber design that eliminates the need for sealing, and thus eliminates the problems ofmolten polymer leakage & injection pressure drop. The benefits of this are numerous. Melttemperatures could be maintained and the lower viscosity used to enable easier filling ofexisting parts or design of thinner-walled parts with corresponding reductions in coolingtimes. Alternatively, the melt temperature could be reduced significantly, while still beingable to fill the same mould (due to the reduced viscosity) but with significantly lowerembodied heat the cooling time can be reduced substantially.This technology could enable UK moulders to increase productivity and competitiveness,regain market share and capitalise on new business opportunities. Existing parts can be cooledmuch quicker; have improved mechanical properties, and potentially lower internal stress andreduce tendency to warp. New design capability for thinner, higher aspect ratio parts wouldalso be possible

欧盟聚合物加工行业继续萎缩，公司努力保持竞争力，虽然能源成本的降低将受到欢迎，但周期时间和部件厚度是财务绩效的关键驱动因素，部件成本是周期时间和机器每小时费率的函数。我们的想法是在熔融聚合物进入型腔之前对其施加超声波能量。这可以使熔体粘度降低多达 60%，从而显着降低不等熔体温度，从而节省加热和冷却能量。我们的目标是为新型传感器/超声波发生器/熔化室设计建立明确的“概念验证”，从而消除密封的需要，从而消除熔融聚合物泄漏和注射压降的问题。这样做的好处是多方面的。保持较低的粘度，以便更容易填充现有零件或设计薄壁零件，并相应减少冷却时间，或者，可以显着降低熔体温度，同时仍然能够。填充相同的模具（由于粘度降低），但内含热量显着降低，冷却时间可以大大缩短。这项技术可以使英国模塑商提高生产力和竞争力，重新获得市场份额并利用现有零件的新商机。冷却速度更快；改善机械性能，并可能降低内应力并减少翘曲倾向，从而可以实现更薄、更高深宽比的零件的新设计能力。