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

欧盟聚合物加工行业继续收缩，公司努力保持竞争力。虽然能源成本的降低是受欢迎的，但循环时间和部件厚度是财务绩效的关键驱动因素，部件成本是循环时间和机器小时率的函数。我们的想法是在熔融聚合物进入腔体之前将超声波能量施加到熔融聚合物中。这可以使熔体粘度降低60%，从而显著降低等效熔体温度，我们的目标是为一种新型换能器/超声焊极/熔体室设计建立一个清晰的“概念验证”，这种设计不需要密封，从而消除了熔融聚合物泄漏和注射压降的问题。这样做的好处是多方面的。熔体温度可以保持和较低的粘度使用，使现有零件或薄壁零件的设计更容易填充，相应减少冷却时间。或者，熔体温度可以显著降低，同时仍然能够填充相同的模具（由于粘度降低），但具有显著降低的残留热量，冷却时间可以大大减少。这项技术可以使英国模具制造商提高生产力和竞争力，重新获得市场份额并利用新的商业机会。现有的部件可以更快地冷却;具有更好的机械性能，并可能降低内应力和减少翘曲倾向。更薄、更高纵横比部件的新设计能力也将成为可能

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