Abstract
This paper reviews some of the recent developments of microcellular injection molding, which is capable of producing parts with excellent dimensional stability using lower injection pressure, shorter cycle time, and less material. Process conditions as well as nano/micro-fillers such as nanoclay and core–shell rubber have a strong influence on cell density and cell size, hence, the final material properties of the molded parts. The addition of nano/micro-fillers at optimum loading levels can generally facilitate the formation of microcellular plastics with higher cell density and smaller cell size leading to superior mechanical properties. The novel integration of a solid plastic surface with a microcellular plastic core via the co-injection molding technique has been investigated to achieve Class “A” surfaces and improved material performance. An improved mathematical model has been developed to simulate the cell growth behavior in the microcellular injection molding process.
References
1 Suh, N. P., in: Innovation in Polymer Processing-Molding. Stevenson, J. F. (Eds.), Hanser Publishers, Munich (1996).Search in Google Scholar
2 Martini, J. E., Waldman, F. A., Suh, N. P.: SPE ANTEC Tech. Papers28, p. 674 (1982).Search in Google Scholar
3 Collias, D. I., Baird, D. G., Borggreve, J. M.: Polymer25, p. 3978 (1994).10.1016/0032-3861(94)90283-6Search in Google Scholar
4 Collias, D. I., Baird, D. G.: Polym. Eng. Sci.35, p. 1167 (1995).10.1002/pen.760351407Search in Google Scholar
5 Matuana, L. M., Park, C. B., Balatinecz, J. J.: Cellular Polymer17, p. 1 (1998).Search in Google Scholar
6 Matuana, L. M., Park, C. B., Balatinecz, J. J.: Polym. Eng. Sci.37, p. 1137 (1997).10.1002/pen.11758Search in Google Scholar
7 Matuana, L. M., Mohanty, A. K., Misra, M.: Paper presented at PPS-20 Symposium, University of Akron, Akron (2004).Search in Google Scholar
8 Baldwin, D. F., Suh, N. P.: SPE ANTEC Tech. Papers38, p. 1503 (1992).Search in Google Scholar
9 Seeler, K. A., Kumar, V.: MD Vol. 38, Cellular Polymers, ASME, p. 93 (1992).Search in Google Scholar
10 Seeler, K. A., Kumar, V.: Journal of Reinforced Plastics and Composites12, p. 359 (1993).10.1177/073168449301200308Search in Google Scholar
11 Shimbo, M., Baldwin, D. F., Suh, N. P.: Polym. Eng. Sci.35, p. 1387 (1995).10.1002/pen.760351710Search in Google Scholar
12 Throne, J., in: Science and Technology of Polymer Processing, Suh, N. P., Sung, N. (Eds.) MIT Press, Cambridge (1979).Search in Google Scholar
13 Baldwin, D. F., Park, C. B., Suh, N. P.: Polym Eng. Sci.36 (11), p. 1446 (1996).10.1002/pen.10539Search in Google Scholar
14 Yun, D. H., Sung, W. C.: Polym Test21, p. 269 (2002).10.1016/S0142-9418(01)00081-2Search in Google Scholar
15 Kumar, V., Nadella, K., Li, W.: SPE ANTEC Tech. Papers49, p. 1722 (2003).Search in Google Scholar
16 Sun, H., Sur, G. S., Mark, J. E.: European Polymer Journal38, p. 2373 (2002).10.1016/S0014-3057(02)00149-0Search in Google Scholar
17 Park, C. B., Baldwin, D. F., Suh, N. P., in: Cellular and Microcellular Materials, Kumar, V., Sealer, K. A. (Eds.), ASME, New York, p. 109 (1994).Search in Google Scholar
18 Ramesh, N. S.: Ph.D. Thesis, Clarkson University, p. 143 (1994).Search in Google Scholar
19 Park, C. B., Baldwin, D. F., Suh, N. P.: Polym. Eng. Sci.35, p. 432 (1995).10.1002/pen.760350509Search in Google Scholar
20 Park, C. B., Suh, N. P.: J. Manuf. Sci. Eng.118, p. 639 (1996).10.1115/1.2831079Search in Google Scholar
21 Park, C. B., Suh, N. P.: Polym. Eng. Sci.36, p. 34 (1996).10.1002/pen.10382Search in Google Scholar
22 Baldwin, D. F., Park, C. B., Suh, N. P.: Polym. Eng. Sci.38, p. 674 (1998).10.1002/pen.10232Search in Google Scholar
23 Han, X., Koelling, K. W., Tomasko, D. L., Lee, L. J.: Polym. Eng. Sci.42, p. 2094 (2002).10.1002/pen.11100Search in Google Scholar
24 Vanvuchelen, J., Perugini, C., Deweerdt, M., Chen, L., Burnham, T.: Journal of Cellular Plastics36, p. 148 (2000).10.1106/6MHJ-JPM8-4L8E-A075Search in Google Scholar
25 Wang, C., Cox, K., Campbell, G. A.: SPE ANTEC Technical Papers41, p. 406 (1995).Search in Google Scholar
26 Shimbo, M., Nishida, K., Heraku, T., Iijima, K., Sekino, T., Terayama, T.: Paper presented at First Int. Conf. Thermoplast. Foam (1999).Search in Google Scholar
27 Shimbo, M.: Foams2000, p. 162 (2000).Search in Google Scholar
28 Xu, J., Pierick, D.: Journal of Injection Molding Technology5, p. 152 (2001).Search in Google Scholar
29 Yuan, M., Turng, L. S., Gong, S., Caulfield, D., Spindler, R., Hunt, C.: Polym. Eng. Sci.44, p. 673 (2004).10.1002/pen.20061Search in Google Scholar
30 Kharbas, H., Nelson, P., Yuan, M., GongS., TurngL. S.: Polymer Composites24, p. 655 (2003).10.1002/pc.10060Search in Google Scholar
31 Chandra, A., Gong, S., TurngL. S., Gramann, P.: SPE ANTEC Tech. Papers50, p. 540 (2004).Search in Google Scholar
32 Chandra, A., Gong, S., TurngL. S., Gramann, P., Cordes, H.: Polym. Eng. Sci.45(1), p. 52 (2005).10.1002/pen.20229Search in Google Scholar
33 Kawashima, H., Shimbo, M.: Cellular Polymers22, p. 174 (2003).10.1177/026248930302200303Search in Google Scholar
34 Kwag, C., Manke, C. W., Gulari, E.: J. Polym. Sci., Part B (Polymer Physics), 37, p. 2771 (1999).10.1002/(SICI)1099-0488(19991001)37:19<2771::AID-POLB6>3.0.CO;2-9Search in Google Scholar
35 Royer, J. R., Gay, Y. J., Desimone, J. M., Khan, S. A.: J. Polym. Sci., Part B (Polymer Physics), 8, p. 3168 (2000).10.1002/1099-0488(20001201)38:23<3168::AID-POLB170>3.0.CO;2-ESearch in Google Scholar
36 Zhang, Z., Handa, Y. P.: J. Polym. Sci., Part B (Polymer Physics)36, p. 977 (1998).10.1002/(SICI)1099-0488(19980430)36:6<977::AID-POLB5>3.0.CO;2-DSearch in Google Scholar
37 Handa, Y. P., Kruus, P., O'Neill, M.: J. Polym. Sci., Part B (Polymer Physics), 34, p. 2635 (1996).10.1002/(SICI)1099-0488(19961115)34:15<2635::AID-POLB11>3.0.CO;2-7Search in Google Scholar
38 Turng, L. S.: Journal of Injection Molding Technology5, p. 160 (2001).Search in Google Scholar
39 Turng, L. S., Kharbas, H.: Polym. Eng. Sci.43, p. 157 (2003).10.1002/pen.10013Search in Google Scholar
40 Winardi, A., Yuan, M., Gong, S., Turng, L. S.: Journal of Cellular Plastics40(5), p. 383 (2004).10.1177/0021955X04047167Search in Google Scholar
41 Selden, R.: Journal of Injection Molding Technology1, p. 189 (1997).Search in Google Scholar
42 Turng, L. S., Kharbas, H.: Intern. Polym. Process.19, p. 77 (2004).10.3139/217.1806Search in Google Scholar
43 Matuana, L. M., Park, C. B., Balatinecz, J. J.: Cellular Polymers17, p. 1 (1998).Search in Google Scholar
44 Chen, L., Sheth, H., Kim, R.: Polym. Eng. Sci.41, p. 990 (2001).10.1002/pen.10800Search in Google Scholar
45 Chen, L., Blizard, K., Straff, R., Wang, X.: Journal of Cellular Plastics38, p. 139 (2002).10.1177/0021955X02038002245Search in Google Scholar
46 Han, X., Zeng, C., Lee, L. J., Koelling, K. W., Tomasko, D. L.: Polym. Eng. Sci.43, p. 1261 (2003).10.1002/pen.10107Search in Google Scholar
47 Han, X., Zeng, C., Wingert, M. J., Lee, L. J., Koelling, K. W., Tomasko, D. L.: SPE ANTEC Tech. Papers50, p. 1723 (2004).Search in Google Scholar
48 Shen, J., Zeng, C., Xu, J., Han, X., Lee, L. J.: Paper presented at PPS-20 Symposium, Akron (2004).Search in Google Scholar
49 Park, C. B., Cheung, L. K.: Polym. Eng. Sci.37, p. 1 (1997).10.1002/pen.11639Search in Google Scholar
50 Chen, L., Wang, X., Straff, R., Blizard, K.: Polym. Eng. Sci.42, p. 1151 (2002).10.1002/pen.11019Search in Google Scholar
51 Baldwin, D. F., Park, C. B., Suh, N. P.: Polym. Eng. Sci.36, p. 1425 (1996).10.1002/pen.10537Search in Google Scholar
52 Ramesh, N. S., Maltwiz, N.: SPE ANTEC Tech. Papers44, p. 1907 (1998).Search in Google Scholar
53 Park, C. B., Behravesh, A. H., Venter, R. D.: Polym. Eng. Sci.38, p. 1812 (1998).10.1002/pen.10351Search in Google Scholar
54 Saunders, J. H., in: Handbook of Polymeric Foams and Foam Technology, Klempner, D., Frisch, K. C. (Eds.), Hanser Publishers, New York (1991).Search in Google Scholar
55 Han, X., Zeng, C., Lee, L. J., Koelling, K. W., Tomasko, D. L.: SPE ANTEC Tech. Papers48, p. 1915 (2002).Search in Google Scholar
56 Zeng, C., Han, X., Lee, L. J., Koelling, K. W., Tomasko, D. L.: SPE ANTEC Tech. Papers48, p. 1504 (2002).Search in Google Scholar
57 Zeng, C., Yag, Y., Han, X., Lee, L. J., Tomasko, D. L.: SPE ANTEC Tech. Papers49, p. 1635 (2003).Search in Google Scholar
58 Jones, S. F., Evans, G. M., Galvin, K. P.: Advance in Colloid and Interface Science80, p. 27 (1999).10.1016/S0001-8686(98)00074-8Search in Google Scholar
59 Xenopoulos, A., Clark, E. S.: PA Plastic Handbook. Hanser Publishers, Munich (1995).Search in Google Scholar
60 Aharoni, S. A.: n-Nylons: Their Synthesis, Structure, and Properties. John Wiley, New York (1997).Search in Google Scholar
61 Murphy, N. S.: Polym. Commun.32, p. 301 (1991).10.7202/056632arSearch in Google Scholar
62 Salem, D. R., Moore, S. A. F., Weigmann, H. D.: J. Polym. Sci., Part B (Polymer Physics)25, p. 567 (1987).10.1002/polb.1987.090250309Search in Google Scholar
63 Borse, N. K., Kamal, M. R., Hasni, S.: SPE ANTEC Tech. Papers49, p. 1413 (2003).Search in Google Scholar
64 Privalko, V. P., Karaman, V. M., Privalko, E. G., Lehmann, B., Friedrich, K.: J. Macromol. Sci. Phys.42, p. 975 (2003).10.1081/MB-120023552Search in Google Scholar
65 Davis, R. D., Jarrett, W. L., Mathias, L. J.: Polym. Commun.40, p. 6597 (1999).10.1016/S0032-3861(99)00189-5Search in Google Scholar
66 VanderHart, D. L., Asano, A., Gilman, J. W.: Chem. Mater.13, p. 3781 (2001).10.1021/cm0110775Search in Google Scholar
67 Medellin-Rodriguez, F. J., Burger, C., Hsiao, B. S., Chu, B., Vaia, R., Phillip, S.: Polymer42, p. 9015 (2001).10.1016/S0032-3861(01)00395-0Search in Google Scholar
68 Maiti, P., Okamoto, M.: Macromol. Mater. Eng.288, p. 440 (2003).10.1002/mame.200390040Search in Google Scholar
69 Yalcin, B., Cakmak, M.: SPE ANTEC Tech. Papers48, p. 2285 (2002).Search in Google Scholar
70 Yuan, M., Turng, L. S., Gong, S., Winardi, A., Caulfield, D.: Journal of Cellular Plastics40(5), p. 397 (2004).10.1177/0021955X04047220Search in Google Scholar
71 Ramesh, N. S., in: Foam Extrusion Principles and Practices, Chapter 5. Lee, S. T. (Eds.) Technomic Publishing Company (2000).Search in Google Scholar
72 Amon, M., Denson, C.: Polym. Eng. Sci.24, p. 1026 (1984).10.1002/pen.760241306Search in Google Scholar
73 Amon., M., Denson, C. D.: Polym. Eng. Sci.26, p. 255 (1986).10.1002/pen.760260311Search in Google Scholar
74 Arefmanish, A., Advani, S. G., Michaelides, E. E.: Polym. Eng. Sci.31, p. 1657 (1991).10.1002/pen.760312305Search in Google Scholar
75 Arefmanesh, A., Advani, S. G.: International Journal of Heat and Mass Transfer35, p. 1711 (1992).10.1016/0017-9310(92)90141-ESearch in Google Scholar
76 Arefmanesh, A., Advani, S. G.: Polym. Eng. Sci.35, p. 252 (1995).10.1002/pen.760350306Search in Google Scholar
77 Zheng, R., Kennedy, P., Xu, J., Kishbaugh, L.: SPE ANTEC Tech. Papers 48 (2002).Search in Google Scholar
78 Osorio, A., Turng, L. S.: Polym. Eng. Sci.44(12), p. 2274 (2004).10.1002/pen.20255Search in Google Scholar
© 2005, Carl Hanser Verlag, Munich
