Microcellular Processing

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Microcellular Processing

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  • Hanser Pub Inc(2003/06発売)
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  • 製本 Hardcover:ハードカバー版/ページ数 186 p.
  • 言語 ENG
  • 商品コード 9781569903445
  • DDC分類 668.493

Table of Contents

    Introduction                                   1  (5)
History 1 (2)
Patents Covering Microcellular Process 3 (2)
Technology
General Description of the MuCell® 5 (10)
Process
Background 5 (1)
The Microcellular Foam Technology 6 (1)
Microcellular Cells: The Theoretical 6 (2)
Solution
Adaptation to Commercial Plastics 8 (3)
Processing Equipment
MuCell Molding Technology 9 (1)
MuCell Extrusion Technology 10 (1)
MuCell Blow Molding Technology 11 (1)
Results and Advantages of the MuCell 11 (1)
Process
MuCell Molding Technology 11 (1)
MuCell Extrusion Technology 11 (1)
MuCell Blow Molding Technology 12 (1)
Summary 12 (3)
SCF Blowing Agent Delivery Systems 15 (12)
Background 15 (1)
Physical Blowing Agent Specification 15 (2)
Nitrogen vs. Carbon Dioxide 17 (1)
SCF Delivery Equipment 18 (9)
Mass Metering vs. Volume Metering 19 (1)
Liquid Pump Systems 19 (1)
Gas Pump Systems 20 (2)
Satellite Gas Systems 22 (1)
SCF Injectors 23 (1)
Injector Valves 23 (1)
Bypass Manifold 24 (1)
References 25 (2)
Microcellular Molding: The Basics 27 (12)
Background 27 (1)
Advantages of Microcellular Molding 28 (1)
Comparison to Other Molding Processes 28 (2)
Microcellular Versus Structural Foam 29 (1)
Molding
Microcellular Versus Gas Assist Molding 29 (1)
Microcellular Versus Chemical Blowing 29 (1)
Agents
Microcellular Molding Equipment Basics 30 (7)
Shut-off Nozzle 31 (1)
Screw Design 32 (3)
Barrel Modifications 35 (1)
Control Modifications 36 (1)
SCF Delivery Equipment 37 (2)
Microcellular Molding: Processing Basics 39 (22)
Introduction 39 (1)
Theoretical Basis for Microcellular 39 (2)
Processing
Process Effects 41 (3)
Effect on Viscosity 41 (1)
Effect on Part Weight 42 (1)
Effect on Cycle Time 43 (1)
Effect on Temperature Settings 44 (1)
Effect on Clamp Tonnage 44 (1)
Beginning Work with the Microcellular 44 (3)
Molding Process
Optimizing the Microcellular Molding 47 (8)
Process
Guidelines 47 (2)
Surface Appearance Optimization 49 (1)
Filled Semi-Crystalline Engineering 49 (1)
Resins
Amorphous Resins 50 (1)
Gating 50 (1)
Additional Considerations 51 (1)
Part Weight Optimization 51 (1)
Cycle Time Optimization 51 (1)
Cell Structure Optimization 52 (1)
Clamp Tonnage Optimization 53 (1)
Minimization Part Warpage 53 (1)
Summary 53 (2)
Troubleshooting the Microcellular Molding 55 (6)
Process
Surface Appearance Issues 55 (1)
Internal Blisters 55 (1)
Surface Blistering 56 (1)
Blowouts 56 (1)
Dimples 57 (1)
Process Issues 58 (1)
SCF out of Solution 58 (1)
Short Shots 58 (1)
Inconsistent Part Weight 59 (1)
Inconsistent Screw Recovery 59 (1)
References 60 (1)
Microcellular Molding: Molded Part 61 (20)
Properties
Background 61 (1)
Effect on Surface Appearance 61 (1)
Effect on Shrinkage 62 (1)
Flexural, Tensile, and Izod Properties 63 (3)
for Polypropylene
Physical Property Changes by Material 66 (5)
Physical Property Modeling 71 (10)
Model for Tensile Strength 71 (1)
Unfilled Materials 72 (1)
Filled Materials 73 (3)
Model for Flexural Strength 76 (1)
Unfilled Materials 76 (1)
Filled Materials 77 (1)
Impact Strength Model and Results 78 (1)
Modeling Summary 79 (1)
References 80 (1)
Moldflow Modeling of Microcellular Molding 81 (10)
Introduction 81 (1)
Theory 81 (5)
Cell Growth 82 (1)
Hydrodynamic Growth Equation 82 (1)
Gas Diffusion Equation 82 (2)
Rheology of the Mixture 84 (1)
Macroscopic Flow 85 (1)
Numerical Algorithm 86 (1)
Experimental Work and Simulation 86 (3)
Summary 89 (2)
References 90 (1)
Microcellular Molding: Case Studies 91 (32)
Background 91 (1)
Mass Air Flow Sensor 92 (2)
Automotive Fasteners and Door Latches 94 (1)
Automotive Interior Trim 95 (1)
Air Distribution Manifold 96 (1)
Engine Intake Manifold Gasket 97 (1)
Automotive Mirror Bracket Support 98 (1)
PC/ABS In-mold Decoration -- Automotive 99 (1)
A-Pillar
Automotive Fuse Box 100(1)
Rear Air Blower Base Connector 101(1)
Cargo AIP System 102(1)
Fan Motor Housing 103(1)
Printer Components 104(3)
Precision Molded Parts 107(1)
Electrical Switches 108(1)
Electronic Control Module (ECM) Connector 109(1)
Power Distribution Center Plate 110(1)
Data Communications Box 111(1)
Electrical Box 112(1)
Electrical Connector 113(1)
Wire Spool 114(1)
High-Wear Components 115(1)
Cable Ties 116(1)
Medical Staple Gun 117(1)
Syringe Plunger Cap 118(1)
Child Gate Panel 119(1)
Thin-Wall Container 120(1)
Bottle Cap 121(2)
Microcellular Molding: Mold and Part Design 123(14)
Background 123(1)
Hot Runner and Sprue Design 124(1)
Cold Sprue and Runner Design 124(2)
Mold Balancing 126(1)
Three Plate Mold Designs 127(1)
Gate Designs 128(1)
Venting 129(2)
Identifying Venting Issues 129(1)
Proper Vent Design 130(1)
Mold Cooling Designs 131(2)
Use of Higher Heat Transfer Materials 132(1)
Mold Finish 133(1)
Mold Materials 133(1)
Part Wall Thickness 134(1)
Part Ribs and Gussets 134(1)
Summary 135(2)
References 135(2)
Microcellular Molding: Economic 137(8)
Considerations
Introduction 137(1)
Specific Areas for Potential Savings 138(3)
Using Microcellular Process
Use of Smaller Molding Machines 138(1)
Reduce Energy Consumption 139(1)
Reduce Colorant Usage 139(1)
Reduce Tooling Costs 140(1)
Increase Parts per Shot 140(1)
Reduce Blowing Agent Costs 141(1)
Total Cost Reduction Due to Microcellular 141(1)
Molding
Summary 142(3)
Microcellular Molding: MuCell Process 145(4)
Alternatives
Introduction 145(1)
Foam Injection Molding 145(1)
Ergocell 146(1)
Chemical Blowing Agents 147(2)
References 148(1)
Microcellular Extrusion 149(14)
Introduction 149(1)
Equipment 150(3)
Polystyrene Microcellular Extrusion 153(2)
Polyvinyl Chloride Microcellular Extrusion 155(2)
Polyolefin Microcellular Extrusion 157(2)
Thermoplastic Vulcanizate Microcellular 159(1)
Extrusion
Summary 160(3)
Microcellular Blow Molding 163(4)
Introduction 163(1)
Equipment 164(1)
Materials 165(1)
Processing Parameters 165(1)
Summary 166(1)
Appendix 1 MIT Patents 167(1)
U.S. Patents 167(1)
International Patents 167(1)
Appendix 2 About Trexel, Inc. 168(3)
U.S. Patents 169(1)
International Patents 169(1)
Published International Patent 170(1)
Applications
Appendix 3 Selected Other Microcellular 171(1)
Patents and Patent Applications
Patents 171(1)
Published Patent Applications 171(1)
Appendix 4 MIT and Trexel References 172(2)
Selected MIT References 172(1)
Selected Trexel References 173(1)
Appendix 5 MuCell Injection Molding Process 174(2)
Sheet
Appendix 6 MuCell Process Troubleshooting 176(2)
Chart
Appendix 7 Glossary 178(6)
Index 184