Physical Foam Injection Molding : Fundamentals for Industrial Lightweight Design

• Record Nr.: UNINA9911007229603321
• Autore: Traut Hartmut
• Pubbl/distr/stampa: München : , : Carl Hanser Verlag, , 2024; ©2024
• ISBN: 1-56990-283-6
• Edizione: [1st ed.]
• Descrizione fisica: 1 online resource (238 pages)
• Altri autori (Persone): WobbeHans
• Disciplina: 668.412
• Soggetti: Injection blow molding; Lightweight materials
• Lingua di pubblicazione: Inglese
• Formato: Materiale a stampa
• Livello bibliografico: Monografia
• Nota di contenuto: Intro -- Preface -- Foreword -- The Authors -- Glossary of Abbreviations -- Contents -- Introduction -- 1 Importance of Foam Injection Molding for Industrial Lightweight Design -- 2 Foam Injection Molding and Its Different Process Variants -- 2.1 Chemical versus Physical Blowing Agents -- 2.1.1 Chemical Blowing Agents -- 2.1.2 Physical Blowing Agents -- 2.2 Processes -- 2.2.1 Low-Pressure Injection Molding Process -- 2.2.2 High-Pressure Process -- 2.2.3 Multi-Component Foam Molding (Sandwich Molding) -- 2.2.4 Foaming with Physical Blowing Agents -- 2.2.4.1 Introduction of the Blowing Fluid in the Area of the Screw -- 2.2.4.2 Injection of the Blowing Fluid via an Auxiliary Unit -- 2.2.4.3 Injection of the Blowing Fluid via an Injection Nozzle -- 2.2.4.4 Injection of the Blowing Fluid via the Screw -- 2.2.4.5 Introducing the Blowing Fluid into the Sprue System of the Injection Mold -- 2.2.4.6 Introduction of the Blowing Fluid in the Area of the Hopper -- 2.2.4.7 Pre-Loading Processes -- 3 Definition and Characteristics of Physical Foam Injection Molding -- 3.1 Properties of TSG Structural Foams -- 3.1.1 Weight Reduction -- 3.1.2 Sink Marks -- 3.1.3 Part Warpage -- 3.1.4 Shrinkage Behavior -- 3.1.5 Mechanical Properties -- 3.1.6 Insulation Behavior against Temperature Gradients -- 3.1.7 Insulation Behavior against Sound -- 3.1.8 Degassing -- 3.1.9 Surfaces -- 3.2 Manufacturing Process of Structural Foams -- 3.2.1 Mass Transfer and Mixing of the Blowing Agent in the Matrix Polymer ; -- 3.2.2 Loading and Compounding of the Single-Phase Mixture in the Plasticizing Unit -- 3.2.3 Foaming and Fixing of the Component in the Mold Cavity -- 3.3 Correlation of the Morphology of the Component Structure with the Process Parameters -- 3.4 Influence of Process Parameters on Component Properties -- 3.4.1 Influence of the Melt Temperature.; 3.4.2 Influence of the Injection Speed -- 3.4.3 Influence of the Mold Temperature -- 3.4.4 Influence of Underdosing in Case of Partial Filling of the Cavity -- 3.5 Measures to Improve the Surface Finish -- 3.5.1 Technologies for Mold Temperature Control -- 3.5.2 Tooling Concepts -- 3.5.3 Surface Coatings of the Cavities -- 3.5.4 Sandwich Foam Injection Molding -- 4 Design Guidelines for Foamed Components -- 4.1 Weight Reduction by Foaming -- 4.2 Basic Design Optimization -- 4.3 Wall Thickness -- 4.4 Outlook for Component Design -- 4.5 Hints for the Mold Design -- 4.5.1 Venting Recommendations -- 4.5.2 Design of Sprue Rod and Manifold -- 4.5.3 Hot Runner Systems -- 4.5.4 Mold Temperature Control -- 4.6 Filling Analysis -- 4.7 Design Guidelines for Foam Injection Molding -- 4.7.1 Three-Phase Model in the Practical Implementation of Design for TSG Components -- 4.7.2 "Design for Function" - A Plea -- 5 Process Simulation -- 5.1 Software Systems -- 5.2 Simulation of Viscosity Reduction / Cell Nucleation and Cell Growth -- 5.2.1 Viscosity Reduction -- 5.2.2 Cell Nucleation and Cell Growth -- 5.3 Meshing / Model Layout -- 5.4 Define Process Parameters for Simulation -- 5.5 Results and Interpretation -- 6 Polymers for Foam Injection Molding -- 6.1 Introduction -- 6.2 Test Specimen -- 6.3 Influence of the Integral Foam Structure on the Characteristic Values -- 6.4 Specific Modification of the Properties of the Foam Polymers -- 6.5 Polymers -- 6.6 Polypropylene (PP) -- 6.7 Polyamides (PA) -- 6.8 Polyoxymethylene (POM) -- 6.9 Polycarbonate (PC) -- 6.10 Nucleating Agents -- 6.10.1 Organic Fillers -- 6.10.2 Inorganic Fillers -- 6.10.3 Fibers -- 7 Engineering Fundamentals of the Foam Injection Molding Machine -- 7.1 Introduction -- 7.2 Clamping Unit -- 7.3 Injection and Plasticizing Unit -- 7.4 Special Equipment -- 7.5 Gas Dosing Station.; 7.6 The Ideal Foam Injection Molding Machine -- 8 Mold Design for Foam Injection Molding -- 8.1 Tooling Basics -- 8.1.1 Gating -- 8.1.1.1 Process Analysis at the Gating Area -- 8.1.1.2 Process Analysis behind the Gating Area -- 8.1.2 Filling Process -- 8.1.3 Venting -- 8.1.4 Mold Temperature Control -- 8.1.5 Ejection -- 8.1.6 Monitoring -- 8.1.7 Mold Surface and Coating -- 8.1.8 Mold and Influence of the Melt -- 8.2 TSG Processes - Application and Mold Design -- 8.2.1 Low-Pressure TSG -- 8.2.2 High-Pressure TSG with Opening Stroke -- 8.2.3 Application Example 1: Soft-Touch Surfaces with High-Pressure TSG -- 8.2.4 Application Example 2: High-Pressure TSG for Flat Visible Components -- 8.2.5 Application Example 3: Low-Pressure TSG -- 9 Application Examples from the Automotive Sector -- 9.1 Introduction -- 9.2 Lock Housing -- 9.3 Door Sill -- 9.4 Headlight Housing -- 9.5 Rear Spoiler Lower Shell -- 9.6 Exterior Mirror Holder -- 9.7 Handle Trim IML -- 9.8 Instrument Panel Carrier -- 9.9 Door Trim Panel and Map Case -- 9.10 Handle Lever for Steering Column Adjustment -- 9.11 Stop Damper -- 10 Application Examples from the Field of Electronic Components -- 11 Application Examples from the Household Sector -- 11.1 Economic Consideration of Foamed Thermoplastic Components -- 11.2 Floor Group White Goods -- 11.3 Base Plate for Power Tools -- 11.4 Irrigation Valve -- 11.5 Running Shoe Sole -- 12 Applications Examples from the Packaging Sector -- 12.1 Margarine Tub -- 12.2 200 ml Yogurt Cup and 900 ml Cup -- 12.3 Recommendations for the Use of Foaming Processes in Thin-Wall ; Packaging -- 12.4 Pallets -- 13 Application Examples from the Field of Medical Technology -- 14 Outlook -- Index.
• Sommario/riassunto: This book provides an in-depth exploration of physical foam injection molding, a process gaining prominence in industrial lightweight design. The authors, Hartmut Traut and Hans Wobbe, along with contributions from industry experts, address the fundamentals, challenges, and advancements of the technology. The book delves into topics such as material data, design guidelines, process simulation, and mold development, emphasizing the need for industry collaboration and investment in training and standards. It is designed to guide both beginners and advanced users in understanding and implementing foam injection molding, with the aim of establishing it as a standard alongside compact injection molding. The work also reflects on historical and patent-related barriers, providing insights into overcoming skepticism and fostering wider adoption. The intended audience includes engineers, industry professionals, and researchers in plastics and manufacturing.