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Novel Injection Moulding Processing for the Production of Low Density Foams based on Innovative Granule Technology

Objective

Our concept is to enable the production of high quality foams from engineering grade thermoplastics using existing injection moulding and extrusion equipment installed in our SME communities. We propose the creation of a novel polymer processing technology. We will develop the ability to foam engineering grade thermoplastics without the need for chemical blowing agents or speciality moulding equipment. Our technology offers many advantages for SME injection moulders & extruders in sectors such as aerospace, automotive and construction. We will: • Eliminate the need to invest in expensive processing machinery to make foam parts • Eliminate the need for chemical blowing agents • Reduce material consumption • Reduce energy consumption through lower process temperatures • Produce low density, consistent foams with excellent mechanical properties • Reduce part cost and finishing operation requirements • Increase manufacturing flexibility We have selected engineering grade thermoplastics, which will be saturated with nitrogen gas at temperatures above Tg, where diffusion rates of gas within the polymer are significantly increased. The granules will then be cooled below Tg, ‘trapping’ the nitrogen molecules within. The granules will be packaged and shipped to SME moulders for use in standard moulding machines. During processing, melting of the polymer will release the trapped nitrogen, producing foam in the moulding machine. We will develop our understanding of melt processing technology to ensure optimum processing speed, density and mechanical performance. Initial trials have already indicated the potential of this process but the technology needs considerable further development for successful commercialisation. We strongly believe that our technological breakthroughs will benefit the European polymer processing community, which is facing significant threats from lower cost imports
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Coordinator

THE BRITISH PLASTICS FEDERATION LBG

Address

Rivington Street 6 Bath Place
Ec2a 3je London

United Kingdom

Activity type

Private for-profit entities (excluding Higher or Secondary Education Establishments)

EU Contribution

€ 693 686

Administrative Contact

Alan Davey (Mr.)

Participants (9)

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MITTETULUNDUSUHING EESTI PLASTITOOSTUSE LIIT (Estonian Plastics Association)

Estonia

EU Contribution

€ 406 787

ASOCIACION ESPANOLA DE INDUSTRIALES DE PLASTICOS - ANAIP

Spain

EU Contribution

€ 423 122

YKI, YTKEMISKA INSTITUTET AB

Sweden

EU Contribution

€ 22 370

THE UK INTELLIGENT SYSTEMS RESEARCH INSTITUTE LIMITED

United Kingdom

EU Contribution

€ 21 413

STRUCTURE-FLEX LIMITED

United Kingdom

EU Contribution

€ 62 516

5M SRO

Czechia

EU Contribution

€ 45 789

POLINTER SA

Spain

EU Contribution

€ 79 669

ZOTEFOAMS PLC

United Kingdom

EU Contribution

€ 150 259

TECNOSTAMP TRIULZI GROUP SRL

Italy

EU Contribution

€ 71 476

Project information

Grant agreement ID: 218346

Status

Closed project

  • Start date

    1 December 2008

  • End date

    30 November 2011

Funded under:

FP7-SME

  • Overall budget:

    € 2 549 036

  • EU contribution

    € 1 977 087

Coordinated by:

THE BRITISH PLASTICS FEDERATION LBG

United Kingdom