A new microcellular foam injection‐molding technology using non‐supercritical fluid physical blowing agents

Yusa, Atsushi; Yamamoto, Satoshi; Goto, Hideto; Uezono, Hiromasa; Asaoka, Fumiya; Wang, Long; Ando, Megumi; Ishihara, Shota; Ohshima, Masahiro

doi:10.1002/pen.24391

Cited by 31 publications

(31 citation statements)

References 11 publications

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“…Research has been conducted on modifications to the standard SCF process developed by MuCell V R . In particular, Yusa et al 47 have successfully shown that machine energy costs and material usage can be reduced by using N 2 and CO 2 at lower pressures than the super critical (SC) state. This was achieved by designing and implementing a similar system to the MuCell V R setup.…”

Section: Super Critical Fluidsmentioning

confidence: 99%

Advances in microcellular injection moulding

Llewelyn

Rees

Griffiths

et al. 2020

Journal of Cellular Plastics

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Injection moulding is a well-established replication process for the cost-effective manufacture of polymer-based components. The process has different applications in fields such as medical, automotive and aerospace. To expand the use of polymers to meet growing consumer demands for increased functionality, advanced injection moulding processes have been developed that modifies the polymer to create microcellular structures. Through the creation of microcellular materials, additional functionality can be gained through polymer component weight and processing energy reduction. Microcellular injection moulding shows high potential in creating innovation green manufacturing platforms. This review article aims to present the significant developments that have been achieved in different aspects of microcellular injection moulding. Aspects covered include core-back, gas counter pressure, variable thermal tool moulding and other advanced technologies. The resulting characteristics of creating microcellular injection moulding components through both plasticising agents and nucleating agents are presented. In addition, the article highlights potential areas for research exploitation. In particular, acoustic and thermal applications, nano-cellular injection moulding parts and developments of more accurate simulations.

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Section: Super Critical Fluidsmentioning

confidence: 99%

Advances in microcellular injection moulding

Llewelyn

Rees

Griffiths

et al. 2020

Journal of Cellular Plastics

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“…In commercial applications, there are three types of injection foaming units that are widely used: (i) MuCell ® by Trexel Inc.; (ii) Optifoam developed by Institute of Plastic Processing (IKV) Sulzer Chemtech; and (iii) Ergocell developed in 2001 by Demag [102]. All studies used super-critical fluids (SCF).…”

Section: Methods and Parameters Associated With Cellulose Nanostrumentioning

confidence: 99%

Cellulose Nanostructure-Based Biodegradable Nanocomposite Foams: A Brief Overview on the Recent Advancements and Perspectives

et al. 2019

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The interest in designing new environmentally friendly materials has led to the development of biodegradable foams as a potential substitute to most currently used fossil fuel–derived polymer foams. Despite the possibility of developing biodegradable and environmentally friendly polymer foams, the challenge of foaming biopolymers still persists as they have very low melt strength and viscosity as well as low crystallisation kinetics. Studies have shown that the incorporation of cellulose nanostructure (CN) particles into biopolymers can enhance the foamability of these materials. In addition, the final properties and performance of the foamed products can be improved with the addition of these nanoparticles. They not only aid in foamability but also act as nucleating agents by controlling the morphological properties of the foamed material. Here, we provide a critical and accessible overview of the influence of CN particles on the properties of biodegradable foams; in particular, their rheological, thermal, mechanical, and flammability and thermal insulating properties and biodegradability.

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“…These problems limit the production and application of foam injection molding to a certain extent. In the field of foam injection molding, many scholars have carried out a lot of research work on conventional physical foam injection molding [3][4][5][6], core-back physical foam injection molding [7][8][9][10] and gas counter pressure (GCP) foam injection molding [9][10][11][12][13]. Core-back foam injection molding [14][15][16][17][18][19][20][21][22][23][24][25] is to inject gas/polymer homogeneous system into the mold cavity first, and use high holding pressure to eliminate the cells generated in the filling process, then open the mold or withdraw the mold core at a certain distance to make the melt foam.…”

Section: Introductionmentioning

confidence: 99%

Effects of process parameters on core-back foam injection molding process

Wu¹,

Zhao²,

Wang³

et al. 2019

Express Polym. Lett.

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Experiments of a new core-back foam injection molding process are described in this paper wherein the blowing agent content [%], mold temperature [°C], shot size [mm], injection speed [mm/s], holding pressure [MPa], holding time [s] and core-back rate [mm/s] were taken as single variables, respectively. The effects and mechanisms of the above parameters on the molding process were studied. The relationships of the parameters with the mechanical properties and the weight reduction effect of the specimens were analyzed. The results show that the effect of blowing agent content, mold temperature, shot size, injection speed and core-back rate in the new method is similar to that of conventional core-back foam injection molding. However, the first stage holding pressure and holding time of the holding process in the secondary filling stage which the new method peculiarly possesses play the same role as shot size and injection speed in conventional foam injection molding, and the second stage holding pressure and holding time play the role of pressure holding in conventional foam injection molding. Compared with the conventional foam injection molding method, the specimens obtained by using the new method have higher weight loss rate, better mechanical properties, and higher specific strength.

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A new microcellular foam injection‐molding technology using non‐supercritical fluid physical blowing agents

Cited by 31 publications

References 11 publications

Advances in microcellular injection moulding

Advances in microcellular injection moulding

Cellulose Nanostructure-Based Biodegradable Nanocomposite Foams: A Brief Overview on the Recent Advancements and Perspectives

Effects of process parameters on core-back foam injection molding process

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