Laser-micromachining of 3D injection molds to fabricate easy-flow polymeric containers

在使用食品和废物包装时，一个常见的问题是容器的最终倒空。食物分解排放是导致全球变暖、酸化和节化的主要因素。因此，完全清空食品包装会带来有趣的环境效益。同样重要的是可持续的废物包装和易于清空的废物容器。不粘住的、自动倒空的集装箱将是一项受欢迎的创新。在这个CRD项目中，加拿大和德国的三名学术研究人员与一家全球代理的散装和食品包装制造商(IPL Inc.)联手。和注塑模具制造者(MoulExpert)，开发一种制造易流动和自清洁塑料容器的工业工艺。我们建议(1)通过流变学研究从根本上评估流入微结构和纳米结构的聚合物之间的关系，(2)建立飞秒激光加工方案，用于制造适合于容器侧壁的成型和脱模的纹理模具表面，以努力在所得到的聚合物部件上诱导所需的易流动自清洁功能，(3)评估在纹理聚合物表面中的润滑剂注入，以制造坚固的光滑自愈合容器内部，(4)将激光微细加工金属模具表面从实验室规模提高到工业水平，并为高通量激光加工建立合适的参数，最后(5)为制造食品或垃圾容器而制作复杂的工业注塑模具。这些成果对工业合作伙伴具有直接价值，因为他们可以借此扩大产品范围并彻底改变包装行业。一名PDF、一名博士和两名UG暑期学生将在该项目的背景下接受培训。他们不仅将在聚合物流变学、激光-物质相互作用和表面润湿等基础研究领域获得有价值的见解，还将在IPL Inc.进行工业注射成型测试时获得应用方面的宝贵见解。这项研究工作的结果将对加拿大人的生活产生直接影响，因为更少的食物浪费和更容易的堆肥处理将总体上减少垃圾填埋废物并保护环境免受进一步排放。此外，加拿大将脱颖而出，成为一个提出革命性技术的国家，该技术也可以应用于基于注塑零件的其他行业。

A frequent problem in the use of food and waste packaging is the final emptying of containers. Food decomposition emissions are a major contributor to global warming, acidification and enthrophication. Thus, there is an interesting environmental gain in completely emptying food packaging. Of similar importance is sustainable waste packaging and easy emptying of waste containers. Non-stick, self-emptying containers would be a welcome innovation. In this CRD project, three academic researchers in Canada and Germany have joint forces with a globally acting bulk and food packaging manufacturer (IPL Inc.) and an injection mold fabricant (Moulexpert) to develop an industrial process for the fabrication of easy-flow and self-cleaning plastic containers. We propose to (1) fundamentally assess the relationship between polymer flow into micro and nanotextures by rheological studies, (2) establish a femtosecond laser machining protocol for fabricating textured mold surfaces suitable for molding and de-molding of container side walls in an effort to induce the desired easy-flow self-cleaning functionality onto the resulting polymer part, (3) assess lubricant-infusion in the textured polymer surfaces for the fabrication of robust slippery self-healing container insides, (4) take laser-micromachining of metallic mold surfaces from the laboratory scale to the industrial level with establishing appropriate parameters for high-throughput laser machining and finally (5) texture a complex industrial injection mold for the fabrication of food or waste containers. The outcomes have direct value for the industrial partners as they can therewith extend their product range and revolutionize the packaging sector.One PDF, one PhD and two UG summer students will be trained in the context of this project. They will gain valuable insights not only in the fundamental research fields of polymer rheology, laser-matter interactions and surface wetting but also with respect to application when running industrial injection molding tests at IPL Inc. The results from this research work will have a direct effect on the life of Canadians, as less food wasted and easier compost handling will overall reduce landfill waste and protect the environment from further emissions. Furthermore, Canada will stand out as a nation bringing forward a revolutionary technology that could be applied to other industries based on injection molded parts as well.