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

在使用食品和废物包装时经常出现的问题是容器的最终排空。食物分解排放是全球变暖、酸化和营养化的主要原因。因此，在完全清空食品包装中存在有趣的环境增益。同样重要的是可持续的废物包装和废物容器的容易清空。不粘，自排空容器将是一个受欢迎的创新。 在这个CRD项目中，加拿大和德国的三位学术研究人员与全球代理散装和食品包装制造商（IPL Inc.）和一个注塑模具制造商（Moulexpert），以开发一个工业过程，制造易流动和自清洁塑料容器。我们提出（1）通过流变学研究从根本上评估聚合物流入微米和纳米纹理之间的关系，（2）建立飞秒激光加工方案，用于制造适于容器侧壁的模制和脱模的纹理化模具表面，以努力在所得聚合物部件上诱导所需的易流动自清洁功能，（3）评估纹理化聚合物表面中的润滑剂注入以用于制造坚固的光滑自修复容器内部，（4）将金属模具表面的激光微加工从实验室规模提升到工业水平，并为高产量激光加工建立适当的参数，最后（5）纹理是一种用于制造食品或废物容器的复杂工业注塑模具。这些成果对工业合作伙伴有直接的价值，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。他们将获得有价值的见解，不仅在聚合物流变学，激光物质相互作用和表面润湿的基础研究领域，而且在IPL公司运行工业注塑测试时的应用。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全面减少垃圾填埋场的废物，并保护环境免受进一步的排放。此外，加拿大将作为一个国家脱颖而出，提出一项革命性的技术，可以应用于其他行业的基础上注塑件以及。

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.