Microcellular Injection moulding

MuCell Technology

Ing. Andrea Romeo

Consorzio Proplast
Laboratorio di Progettazione Avanzata

Summer School, New trends in plastics engineering - Bellignat, 9-07-2013

The MuCell-Process-Technology

1. MuCell Basics and Function

2. Strategic Advantages
3. MuCell Design Rules
4. General MuCell Examples
MuCell Basics and Function

Function and technical equipment

Two Main Characteristics describe the
MuCell Process

1. Lowering of the viscosity of thermoplastic resins

by controlled feeding of gas (either N2 or CO2)
into the melt

2. Creation of a microcellular Structure in the part

core by gas expansion in the cavity (Injection
Moulding) or after the die (Extrusion)
 The MuCell Process

Creating a single phase solution injecting the SCF

(super critical fluid) into the thermoplastic melt during
screw recovering

Creating a single
phase solution

Injecting
SCF
 The MuCell Process
Dissolving SCF into the melt
Screw flights break-up SCF stream
Mixing flights cause SCF to divide
into smaller bubbles
and then dissolve

Inject SCF

Diffusion Complete SCF Polymer

 The MuCell Process

Foaming occurs during injection into the mold

. .
. . .. . . .
.
. .. .
.
. .
. . .
. . . .
. . . . .

Time Time

Low pressure in the mold cause SCF to form cells

Cells grow until the material freezes or the mold cavity is full
 MuCell Moulding Technology
Scanning Electron Microscope (SEM) microstructure

Source:

Material: Nylon 66 with 35% glass fibers

MuCell Moulding Technology

Compact skin

Foamed core

Compact skin
 MuCell Moulding Technology

Control of Foaming
Controlling cell size and the number of cells
Correct SCF level: Higher SCF creates more cells
(Always a limit to how much SCF)
Rate of pressure drop (controlled primarily by
injection speed)

Trexel Confidential 10
MuCell Strategic Advantages

MuCell Design Rules

Limitations of Solid Molding
Influence on part quality
Saving potentials
 MuCell Design Rules
Limitations of Solid Molding
Solid molding is constrained by:
Need to push plastic from gate to end of fill without freezing off
Need to pack the part along the entire flow length
To obtain uniform shrinkage for dimensional stability
To eliminate sink marks and vacuum voids

These processing limitations impose design restrictions

that affect the ability to reduce wall thickness

The MuCell Process removes these restrictions!

 MuCell versus Solid Molding

Reduced viscosity (10% to 15% for a 30% glass fiber)

Increased flow length
Lower fill pressures
Cell growth replaces the pack/hold phase, resulting in
lower and more uniform cavity pressure
Pack pressure does not need to go from gate to end of flow
Pack takes place locally
Lower pack and hold pressures
Shorter pack and hold times
Reduced cavity pressures
Lower clamp forces
Less molded-in stress = Reduced warpage
Reduced cooling required

Trexel Confidential 15
 Strategic Benefit Capacity Use
(Reduced cycle time)

Opening/Eject./ Injection Pack&Hold Cooling

Closing

Solid

MuCell T depends on
material type,
part design and
mould cooling
Hold time (nearly)
eliminated

Reduced cooling time

More exchange
Less temperature
 Delete parameter hold
The parameters hold pressure pH and hold time tH
are deleted by the MuCell Foaming Process.
Part formation by cell growth, independently of part weight
Counteraction against shrinkage not by additional packed mass
Equal pressure distribution in the cavity (significant less difference
in pressure levels near injection point and far injection point)

Example:
Connector Housing
with PBT GF 30

Decoupling of part dimensions

and part weight
Trexel Confidential
 Strategic Benefit Machine Size
(reduction of hydraulic pressure)

Solid MuCell
Peak pc = 1045 bar
Peak pc = 448 bar

Screw
position

Data Com Connector,

PBT with 30 % glass
57 % reduction in peak cavity pressure
Due to viscosity reduction, less resin volume, no pack &
hold pressure
Longer tool life Trexel Confidential 18
 Microcellular Foam Properties

Without foam 10% physical foam

DSC - Curve: PBT GF 30 with DSC - Curve: PBT GF30 with
mould temp. 80C mould temp. 30C

Source: Ticona Source: Ticona

Melting temperature : 225,4C Melting temperature: 225,0C

Heat of Fusion (H): 40,67 J/g Heat of Fusion (H): 41,93 J/g
Crystallinity Level is identical

Trexel Confidential 19
 Strategic Benefit Quality
(faster product release)

Overall Width- Rectangular Box

Width- Open side

96,200
95.9 96,100
96,000
200 95,900
95,800
Gate 95,700
95,600
95,500
1
1 2 3 4 5
2 Position
3 (Gate at # 4)

Cav1- Solid Cav1- MuCell Cav2- Solid Cav2MuCell

4
5

More consistent & predictable MuCell dimensions simplify

mould design & reduce the number of costly iterations

Trexel Confidential 20
 Maximizing MuCell Advantages

Phase I: existing mold - Learning and

Validation
Current designs at Pre-production stage or
earlier
Establish comparisons with solid parts

Phase II: Using New Design Rules

Design for MuCell with thinner walls, wall
thickness variations, and different rib
structures
Trexel Confidential
 MuCell design rules

Designing for function

Differences in Wall Thicknesses
Shrinkage
Mechanical properties
 Designing for MuCell

If parts are designed for the

MuCell Process at the outset,
parts weight can be reduced
>20 %

Trexel Confidential
 MuCell Vs Solid Molding

Foam expands more into thick sections -

less in thin sections
Foam expands until the flow front freezes
Freeze happens more quickly in thin sections
Necessary to push the plastic further into thin sections to
have complete fill
Gate into thin sections, flow into thick sections
Expansion will eliminate sink marks

Trexel Confidential 27
 Differences in Wall Thicknesses
Filling from thin to thick

Recommended Injection in solid

injection with MuCell (with MuCell still possible)

Wall to rib ratio 1:1 possible

Conventional design MuCell design

Trexel Confidential 28
 Shrinkage

in [mm]

599 600 599 598 Solid dimensions

599 599 599 599 MuCell dimensions

Shrinkage is a little bit higher but much more uniform

(in flow and in X-flow direction)
 Mechanical Properties
Influence for mechanical properties of gate location on
test specimens and on real parts

End of flow
Specimens Mould:
3D Part Mould:

Thickness = 4 mm

Strength on test specimens

Thickness = 2 mm

End of flow

Near the gate

Injection point
 Designing for Function
Example: 15% weight reduction through wall
thickness optimization and 4 % with density
reduction
1.11 mm at 1.22 mm
1.75 mm at tip of ribs
top of front
wall

1.55 mm at 1.49 mm
1.31 mm
base of at base
1.12 mm
front wall

1.12 mm
Gate Location

Trexel Confidential 1.2 mm 36

 Part Design Wall Thickness

Weight reduction is highly dependent on flow factor

- Ratio of Flow Length to Part Thickness
Weight reduction also dependent on
- Part Thickness 40
- Material
35
- Gate Location % Wt. Reduction envelop
30
as a function of flow factor
Weight reduction [%]

25 Low viscous (PA) top

High viscous (PC gf30 fr) low
20

15

10

0
50 75 100 125 150 175 200 225 250
Flow Factor

Trexel Confidential 37
General MuCell examples

Glass fibers and flatness

Appearance Applications
Performance measurement of flatness
3.2 mm test plaques
Less warpage
more uniform mechanical performance

PP 40 % LGF Solid PP 40 % LGF Solid

PP 40 % LGF MuCell PP 40 % LGF MuCell

Trexel Confidential 39
 MuCell Appearance Applications

Modified materials
(PA 6, PA 6/6 & PBT)

Mould based solutions

Appearance parts in
mass production with
IMD Technology

Trexel Confidential 40
 MuCell Applications
Automotive
Office-
Equipment

Industry
& Semi
Electric/ Packaging
conductors
Electronic

Trexel Confidential 41
Packaging Super Light Injection Molding

MuCell Benefits:
Reduce clamp tonnage (smaller machines)
4+4 cavities on 350 t instead of 500 t
Higher cavitation
Reduced injection pressure
Design reduced wall thickness, -15 %
Improved performance with IML Technology
Use thinner labels (lower material viscosity)
Weight reduction = 5,5 %
Trexel Confidential 42
 Circular Saw (Base Plate)
Replacement of aluminium die-cast part by MuCell base plate
of PA 6.6 GF55
 Wire Harness

Key MuCell Objectives:

Dimensional stability
Flatness of parts and ease of assembly

Key MuCell Results:

Weight reduction = 8 %
Cycle time reduction = 10 %
Dramatically improved dimensional stability
and warpage reduction

44
 MuCell Electronic Housing

MuCell Benefits
Smaller injection moulding machine
Shorter cycle time
Improved flatness, reduced warpage, accurately fitting
Improved breaking behaviour at destructive
testing
 MuCell Car Key

MuCell Benefits
Equal shrinkage with different wall thicknesses on the
part (reduced warpage)

Elimination of sink marks

Achieve Class-A surface for application of high
gloss scratch resistant clear lacquer
 Valeo - Interior Bezel
General Motors - Opel Corsa
2002 SPE Automotive Innovation
Award Winner
Quality Improvement
Eliminated sink marks Category: Process / Enabling
Technologies
Improved dimensional
stability
Process Improvement
Clamping force reduced
from 250-tons to 75-tons

10% Weight savings Cycolac CRT 3370 ABS - glass filled

Not necessary to preform the IM
label (label is thinner, because of
less wash-out effect)

MuCell is generally targeted to non-aesthetic parts unless the

part is covered, in-mold decorated, in-mold labeled or painted
Trexel Confidential 47
 MuCell Torso Airbag Cover

Key MuCell Objectives:

Elimination of different shrink
(elimination of sink marks caused by different cross
sections)
Design freedom
Painted

Key MuCell Results:

No deviation in shape (no sink marks)
Improved dimensional stability
Improved function of the living hinge
Smaller machine requirement
(300 t instead of 500 t in solid)
Successful painting
Trexel Confidential 48
 MuCell HVAC Systems

Key MuCell Objectives

Avoidance of warpage
Machine size reduction
Weight savings

Key MuCell Results

9-12% weight reduction 20% Talc Filled PP
Machine size reduction
from 1000 tons to 600 tons
Cycle times savings of 10-15%
Improved product assembly
Fewer mold corrections

49
 MuCell Fan Shrouds

Key MuCell Objectives

Cycle time savings
Machine size reduction
Weight savings
Warpage reduction

Key MuCell Results

Typical weight reduction 7-10%
Machine size reduction
from 1000 tons to 500 tons
Cycle time savings of 25-40%
200% improvement in fatigue
resistance

Typical materials:
PA 66 GF 30
PP GF 30
PA 6 G+M 43

Chrysler
50 RS Dual fan shroud
 MuCell Cam cover

MuCell advantages
30 % reduced machine size (350 instead of 500 t for
conventional molding)

Improved cycle times, which allow for simultaneous

production and assembly process

Lighter part
Improved flatness
Trexel Confidential 51
 MuCell Sun Roof Frame

MuCell Benefits
Reduced amount of components, tools and assembling
processes

Dramatically reduced warpage in spite of a complex

geometry

Only one optimization loop required after tool

construction (shorter project time)
Daimler W212 Door Trim
Winner 2009 in category
Interiors
MuCell parts (abs):
Carrier:
Thinner wall thickness by lower
viscosity
10 % density reduction by MuCell
Tandem-Mould Technology plus
MuCell (with > 50 % cycle time red.)
Wall thickness to rib ratio = 1:1
Map Case:
Wall thickness to rib ratio = 1:1
Deletion of one tool and an
additional assembling process (by
MuCell Design)
Advantages with IML Technology
(lower pressure levels)
 Conclusion
MuCell process allows significant savings
Very short Pay back

Valuable benefits:
Weight reduction
-Due to the microcellular expansion, usually 8-10%
-Via pre-design/optimization
of the part (wall thickness reduction) up to 35%
Cycle time reduction up to 50%
Injection pressure reduction 40 to 60%
Machine size reduction up to 60%
Warpage/deformation reduction
Avoidance of sink marks
Uniform directional dimensional shrinkage
Time to market reduction (fewer mould modifications to dimensional conformity)
Lower energy consumption/Environmental impact
PROPLAST, Trexel, ENGEL partnership
To promote and disseminate the Mucell technology

Demo installation
At Proplasts site (Tortona, Italy)
IMM: Engel 180 tons, screw: 55 mm
Shot weight: 100-500 g
Mucell unit - Co2 or Nitrogen

Goals
Support customers at every stage of the technology implementationa and application
Part design for Mucell (optimization, moldflow Mucell simulation etc)
Support to mould design
Mucell moulding trials / mould piloting

R&D projects ongoing

Aestethical aspect optimization (class A surface, material design and optimization)
Combination with H&C technologies (pressurised water, induction)
Thank you for your attention

Ing. Andrea Romeo

Consorzio Proplast
Advanced Design Lab
andrea.romeo@proplast.it
+39 01311859743
www.proplast.it

Summer School, New trends in plastics engineering - Bellignat, 9-07-2013