This study presents a method for the determination of the dynamic pressure-dependent solidification of polycarbonate (PC) during flow using high pressure capillary rheometer (HPC) measurements. In addition, the pressure-dependent solidification was determined by isothermal pressure-volume-temperature (pvT) measurements under static conditions without shear. Independent of the compression velocity, a linear increase of the solidification pressure with temperature could be determined. Furthermore, the results indicate that the relaxation time at a constant temperature and compression rate can increase to such an extent that the material can no longer follow within the time scale specified by the compression rate. Consequently, the flow through the capillary stops at a specific pressure, with higher compression rates resulting in lower solidification pressures. Consequently, in regard to HPC measurements, it could be shown that the evaluation of the pressure via a pressure hole can lead to measurement errors in the limit range. Since the filling process in injection molding usually takes place under such transient conditions, the results are likely to be relevant for modelling the flow processes of thin-walled and microstructures with high aspect ratios.
In recent years, the demand for polymer compound solutions for the application of bipolar plates in polymer electrolyte membrane fuel cells (PEMFC) has increased continuously due to significant cost and lifetime advantages compared to metallic solutions. The main challenge of the compounds is the high filler content required to ensure sufficient electrical conductivity of the bipolar plates. The associated increase in viscosity and simultaneously increased thermal conductivity limit the conventional injection molding process in terms of achievable flow path length to wall thickness ratios (plate aspect ratio). In order to evaluate the extent to which highly modified electrically conductive polymer material systems can be processed into thin-walled and highly dimensionally stable bipolar plates, an injection compression molding process with dynamic mold temperature control (ICM-DT) has been developed. For this purpose, a compound was prepared from polypropylene (PP) and graphite-flakes. The compound was characterized with respect to the achieved filler content, the electrical conductivity, as well as the pressure- and temperature-dependent solidification range. The ICM-DT experiments were carried out by varying the maximum mold temperature and the compression force. In addition, the process was designed with multiple compression and decompression steps to account for a possible pressure-dependent solidification of the compound. The plates were characterized with respect to the achieved plate aspect ratio and the flow-path-dependent dimensional thickness stability. It was shown that the plate aspect ratio could be increased by up to 125% with the maximum filler content compared to conventional injection molding processes provided in the literature. With the multi-stage ICM-DT process, it was also possible to optimize the thickness dimensional stability with a maximum deviation of 3% over the flow path.
In this study, the influence of pressure during processing on the refractive index (RI) of polycarbonate (PC) was investigated by transmission measurements on glass‐filled samples with a spectrometer. In order to isolate the pressure dependence of the RI from other influencing parameters such as cooling rate, orientation and stress states, the samples were prepared in a pressure‐specific volume‐Temperature (pvT) instrument under constant cooling rate and temperature history and without shear effects. Subsequently, the RI was determined at the intersection of the dispersion curves of the glass and the polymer by evaluating the wavelength of the maximal transmission of the samples. The mean RI over the entire cross section of the sample is determined by the transmission measurements without complex sample preparation. The investigations show that the RI of PC increases by 3.26 E‐6 per bar with increasing pressure. POLYM. ENG. SCI., 60:512–516, 2020. © 2019 The Authors. Polymer Engineering & Science published by Wiley Periodicals, Inc. on behalf of Society of Plastics Engineers.
Integrative simulation techniques for predicting component properties, based on the conditions during processing, are becoming increasingly important. The calculation of orientations in injection molding, which, in addition to mechanical and optical properties, also affect the thermal shrinkage behavior, are modeled on the basis of measurements that cannot take into account the pressure driven flow processes, which cause the orientations during the holding pressure phase. Previous investigations with a high-pressure capillary rheometer (HPC) and closed counter pressure chamber (CPC) showed the significant effect of a dynamically applied pressure on the flow behavior, depending on the temperature and the underlying compression rate. At a constant compression rate, an effective pressure difference between the measuring chamber and the CPC was observed, which resulted in a stop of flow through the capillary referred to as dynamic compression induced solidification. In order to extend the material understanding to the moment after dynamic solidification, an equilibrium time, which is needed until the pressure signals equalize, was evaluated and investigated in terms of a pressure, temperature and a possible compression rate dependency in this study. The findings show an exponential increase of the determined equilibrium time as a function of the holding pressure level and a decrease of the equilibrium time with increasing temperature. In case of supercritical compression in the area of a dynamic solidification, a compression rate dependency of the determined equilibrium times is also found. The measurement results show a temperature-invariant behavior, which allows the derivation of a master curve, according to the superposition principle, to calculate the pressure equilibrium time as a function of the holding pressure and the temperature.
In addition to conventional injection‐compression molding and injection molding with dynamic process temperature control, a synergistic combination of both processes has recently been applied in dynamic temperature‐controlled injection‐compression molding. The two‐dimensional holding pressure effect in combination with the long maintenance of the flowability of the melt due to high mold temperature enables particularly large flow path to wall thickness ratios. In the most cases, only the optimized molding of microstructures and aspect ratios is considered without including the changed internal structure of such manufactured components. In the course of this investigation, the influence of different process strategies under variation of the mold temperature on production‐related anisotropies in the mechanical properties and stress crack sensitivity of thin‐walled polystyrene components was examined. The determined mechanical properties are significantly below the values given in the data sheet of the material in the adapted process variant of injection‐compression molding with high mold temperature. However, the results also show a clear homogenization of the direction‐ and flow path‐dependent mechanical properties. In contrast, components produced in this way tend to show increased environmental stress crack sensitivity. This could be attributed to significantly reduced orientations as a result of the favorably proceeding orientation relaxation.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.
hi@scite.ai
10624 S. Eastern Ave., Ste. A-614
Henderson, NV 89052, USA
Copyright © 2024 scite LLC. All rights reserved.
Made with 💙 for researchers
Part of the Research Solutions Family.