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Development of Innovative Gas-Assisted Foam Injection Molding Technology.

机译：开发创新的气体辅助泡沫注射成型技术。

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摘要

Injection molding technology is utilized for a wide range of applications from mobile phone covers to bumper fascia of automotive vehicles. Foam injection molding (FIM) is a branched manufacturing process of conventional injection molding, but it was designed to take advantage of existing foaming technology, including material cost saving and weight reduction, and to provide additional benefits such as improvement in dimensional stability, faster cycle time, and so on. Gas-assisted injection molding (GAIM) is another supplemental technology of injection molding and offers several advantages as well. This thesis study takes the next step and develops innovative gas-assisted foam injection molding (GAFIM) technology, which is the result of a synergistic combination of two existing manufacturing technologies, FIM and GAIM, in order to produce a unique thermoplastic foam structure with proficient acoustic properties. The foam structure manufactured by GAFIM consists of a solid skin layer, a foam layer, and a hollow core; and its 6.4-mm thick sample outperformed the conventional 22-mm thick polyurethane foam in terms of the acoustic absorption coefficient. With respect to foaming technology, GAFIM was able to achieve a highly uniform foam morphology by completely decoupling the filling and foaming phases. Moreover, the additional shear and extensional energies from GAFIM promoted a more cell nucleation-dominant foaming behavior, which resulted in higher cell density and smaller cell sizes with both CO2 and N2 as physical blowing agents. Lastly, it provided more direct control of the degree of foaming because the pressure drop and pressure drop rate was controlled by a single parameter, that being the gas injection pressure. In summary, innovative, gas-assisted foam injection molding technology offers not only a new strategy to produce acoustically functioning thermoplastic foam products, but also technological advantages over the conventional foam injection molding process. Gas-assisted foam injection molding can become the bedrock for more innovative future applications.
机译：注射成型技术被广泛用于从手机套到汽车保险杠装饰板的应用。泡沫注射成型（FIM）是常规注射成型的分支制造工艺，但其设计目的是利用现有的发泡技术，包括节省材料成本和减轻重量，并提供其他好处，例如改善尺寸稳定性，缩短周期时间等等。气体辅助注射成型（GAIM）是注射成型的另一种补充技术，并且还具有许多优点。本论文的研究工作下一步，开发了创新的气体辅助泡沫注射成型（GAFIM）技术，该技术是两种现有制造技术FIM和GAIM协同结合的结果，目的是生产出一种精湛的独特热塑性泡沫结构声学特性。 GAFIM生产的泡沫结构由实心皮层，泡沫层和空心组成。其6.4毫米厚的样品的吸声系数优于传统的22毫米厚的聚氨酯泡沫。在发泡技术方面，GAFIM通过完全分离填充和发泡相来实现高度均匀的泡沫形态。此外，GAFIM产生的额外剪切和拉伸能促进了更多的以气泡成核为主的发泡行为，这导致较高的气泡密度和较小的气泡尺寸，同时使用CO2和N2作为物理发泡剂。最后，由于压降和压降速率由单个参数（即注气压力）控制，因此可以更直接地控制发泡程度。总之，创新的气体辅助泡沫注射成型技术不仅提供了生产具有声学功能的热塑性泡沫产品的新策略，而且还提供了优于常规泡沫注射成型工艺的技术优势。气体辅助泡沫注射成型可以成为未来更多创新应用的基础。

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  • 作者

    Jung, Peter Ungyeong.;

  • 作者单位

    University of Toronto (Canada).;

  • 授予单位 University of Toronto (Canada).;
  • 学科 Mechanical engineering.;Plastics.
  • 学位 Ph.D.
  • 年度 2013
  • 页码 218 p.
  • 总页数 218
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类
  • 关键词

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