A new concept for ultrasonic flow enhancement in injection moulding, to eliminate polymer leakage problems

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TheEU polymer processing industry continues to contract, with companies struggling toremain competitive. Whilst energy cost reductions would be welcomed, cycle time andcomponent thickness are key drivers of financial performance, with parts costed as a functionof cycle time & machine hourly rate.Our idea is to apply ultrasonic energy into the molten polymer just before it enters the cavity.This can yield as much as 60% reduction in melt viscosity, enabling a significant reduction inequivalent melt temperature, thus saving both heating & cooling energy.Our goal is to establish a clear ‘proof of concept’ for a novel transducer/sonotrode/meltchamber design that eliminates the need for sealing, and thus eliminates the problems ofmolten polymer leakage & injection pressure drop. The benefits of this are numerous. Melttemperatures could be maintained and the lower viscosity used to enable easier filling ofexisting parts or design of thinner-walled parts with corresponding reductions in coolingtimes. Alternatively, the melt temperature could be reduced significantly, while still beingable to fill the same mould (due to the reduced viscosity) but with significantly lowerembodied heat the cooling time can be reduced substantially.This technology could enable UK moulders to increase productivity and competitiveness,regain market share and capitalise on new business opportunities. Existing parts can be cooledmuch quicker; have improved mechanical properties, and potentially lower internal stress andreduce tendency to warp. New design capability for thinner, higher aspect ratio parts wouldalso be possible