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Injection Molded Integral Foam Structures with Pronounced Density Reduction

An injection moulding process for the manufacturing of integral foam structures with pronounced density reduction was investigated. The process characteristics as well as the performance of the obtained integral foam structures were evaluated, where a non-reinforced, a mineral filled, and a short glass-fibre reinforced polypropylene was used for the experiments. A chemical foaming agent as well as physical gas loading of the melt with nitrogen was employed.

The processing approach proved to be feasible similar as the conventional injection moulding, where the mechanical properties were regarded as a measure. An effective weight saving up to 25 % was possible, referring to the bending stiffness and strength, when the specimen thickness was 5 mm or less. This was achieved with a density reduction of up to 75 % in the core section. Up to that level of density reduction, the robustness of the processing was secure.

A modelling of the foamed structures meeting the specifics of the process enables the prediction of stiffness and strength properties. Of predominant concern is the characteristic surface layer thickness that decreases with increasing density reduction and increases with growing overall thickness, but can only be slightly changed by adjustments of the process settings.

Lesen Sie die deutsche Zusammenfassung auf Kunststoffe.de
Author
 Norbert Müller

Norbert Müller
Lehrstuhl für Kunststofftechnik (LKT)
Universität Erlangen-Nürnberg

Information

Free keywords: foam injection molding, lightweight design, MuCell, precision mold opening
Institute / chair: Technische Fakultät der Universität Erlangen-Nürnberg
Language: German
Technical consultant for expert services: Prof. Dr.-Ing. Dr. h.c. Gottfried W. Ehrenstein (Betreuer), Prof. Dr.-Ing. Rainer Renz
Publication year: 2006
Provider: Wissenschaftlicher Arbeitskreis Kunststofftechnik (WAK) / Kunststoffe.de

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