Gas-Assisted Injection Moulding of one and multi-component parts

  • Erikson, Torbjörn (Project Participant)
  • Rasmussen, Henrik K. (Project Participant)

    Project Details

    Description

    Gas-assisted injection moulding (GAIM) is a two-component process, where a mould is filled partly with a polymer melt (a thermoplastic material), followed by the injection of inert gas into the core of the polymer melt.

    Parts produced by gas-assisted injection moulding are hollow. Consequently they use fewer resources than solid parts produced by conventional injection moulding. Complex parts consisting of both thick and thin sections can be produced (unlike in conventional injection moulding) with lower material usage, lower machine investment, better surface finish (better quality) and shorter cycle (production) times, compared to conventional injection moulding.

    In this project it is the intention to develop two well-monitored equipments. One, allowing the experimental investigation of the gas-polymer displacement process, developing the internal surface in a product. The other equipment, based on a simple compression moulding technique, should allow the investigation of the replication of the mould surface in the plastic, incorporating an insert with well-defined microstructures in the mould.

    The equipments should be prepared for later multi component displacement investigations, where more than one polymer is displaced simultaneously.

    It is the major target of this Ph.D. project to gain a more thorough understanding of the underlying physical processes responsible for the formation of the inner and outer surface in a plastic product.

    In order to gain understanding of the polymer melt distribution in the GAIM process, we have to resort to a numerical model of the process. Modelling of the GAIM process, with respect to the real fluid behaviour of the polymer melt (polymer melts are highly complex fluids), even in a simple geometry have not yet been resolved. A more detailed understanding of flow properties and the influence of material parameters, e.g. the rheology is needed. It is the purpose to model the combined flow of a gas and a highly viscous polymer melt and the filling of the micrustructures in the mould surface numerically, with the Finite Element Method, to obtain an understanding of both filling processes.
    StatusFinished
    Effective start/end date01/09/200101/09/2004

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