An innovative, disruptive, advanced technology for ultrasonic flow enhancement of injection moulding that significantly reduces cooling times improves productivity

Informations projet

Ultramelt

N° de convention de subvention: 650989

DOI

10.3030/650989

Projet clôturé

Date de signature de la CE 8 Octobre 2014

Date de début 1 Octobre 2014

Date de fin 31 Mars 2015

Financé au titre de

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies – Nanotechnologies

Coût total

€ 71 429,00

Contribution de l’UE

€ 50 000,00

Coordonné par

THE TECHNOLOGY RESEARCH CENTRE LIMITED
United Kingdom

Periodic Reporting for period 1 - Ultramelt (An innovative, disruptive, advanced technology for ultrasonic flow enhancement of injection moulding that significantly reduces cooling times improves productivity)

Période du rapport: 2014-10-01 au 2015-03-31

Résumé du contexte et des objectifs généraux du projet

Injection moulding is a large portion of the EU thermoplastics processing industry. In 2008, its value was €55 bn, but fell to €43 bn in 2009. The industry continues to contract, struggling against low cost economies. While energy cost savings are welcome, cycle time dominates cost so reducing it is key & will increase productivity. Cycle time is dominated by cooling time, which depends on many factors including melt temp. Polymers are often heated well above the ideal melt temperature to aid injection by lowering viscosity. Similarly, very high injection speeds/pressures are used. But we show later that these methods have drawbacks. Our idea is to apply ultrasonic energy into the molten polymer just before it enters the cavity. This can achieve as much as 60% reduction in melt viscosity, enabling a significant reduction in melt temperature while still being able to fill the mould. Lower embodied heat reduces heating/cooling time & energy. Key benefits are described in detail later, but the main ones are that melt temperatures can be maintained and the lower viscosity used to enable easier filling of existing parts with lower internal stresses; melt temperature can be reduced significantly, reducing thermal degradation, energy consumption & cooling time. Or melt temp is maintained and much longer flow paths or thinner wall sections can be filled, offering a step change in design for thinner parts with even shorter cooling time. The ultimate goal of the Phase 2 project is to achieve market readiness of our patented ‘Ultramelt’ process, with follow-on Phase 3 achieving commercialisation in the EU marketplace. This technology could enable EU moulders & extruders to increase productivity by 50%, increasing competitiveness, enabling them to regain market share and capitalise on new business opportunities.

Travail effectué depuis le début du projet jusqu’à la fin de la période considérée dans le rapport et principaux résultats atteints jusqu’à présent

The research for the Feasibility Study has been completed and the report compiled, as attached.

Progrès au-delà de l’état des connaissances et impact potentiel prévu (y compris l’impact socio-économique et les conséquences sociétales plus larges du projet jusqu’à présent)

The expected final result is the feasibility report which is complete and attached. There are no other impacts of the Phase 1 project to report.

TRC website. No other relevant images.