Slide 1: Supporting the Plastics Industry: Gas Assist Injection Molding
Supporting the Plastics Industry Application Capability: Gas Assist Injection Molding Air Products Internal Use Only 1
Slide 2: The GAIM Process
The GAIM Process 1. Slug of plastic is injected 2. Part of slug in contact with mold crusts and hardens 3. N2 is injected and takes path of least resistance 4. Pressure is held till polymerization is cured 5. N2 is released
Slide 3: GAIM Advantages
GAIM Advantages Increase: Decrease: • Design Freedom • Clamp Tonnage • Productivity • Energy Required • Efficiency • Machine Size • Strength • Cycle Time • Rigidity • Part Weight • Needed Plastic • Cooling Time • Oxidation • Scrap 3 Air Products Internal Use Only
Slide 4: Quantifiable Advantages
Quantifiable Advantages Clamping Pressure Plastic Weight Reduction in Cycle Reduction Reduction Times • 3000 psi vs. 25000 • Thin-walled parts: • Up to 50% due to psi for 1-2% reduction plastic reduction, conventional • Thick parts: Up to increased injection 40% reduction convection cooling and decr
Slide 5: Why Use Nitrogen?
Why Use Nitrogen? ● Required to combat oxidation at polymer melt temperatures ● Extent of oxidation will dictate required nitrogen purity – nitrogen available in a wide range of purities to supply requirements ● Other Benefits: - Inexpensive - Easily compressible - Dry - Can be delivered easily at c
Slide 6: Application Examples
Application Examples ●Heavy ribs and bosses can be incorporated in your design without fear of sinks on the part surface. The ribs may actually be thicker than the nominal wall 6 Air Products Internal Use Only
Slide 7: Application Examples
Application Examples ● This part was originally molded in structural foam. With gas assist, the producer was able to reduce the shot weight by 1 pound, reduce cycle time by 34%, and limit the paint process to 1 coat. 7 Air Products Internal Use Only
Slide 8: Applications and End Goals
Applications and End Goals Large, sheet-like, Complex parts Tube-and rod-like structural parts consisting of both Molding Type parts with a built-in gas- thin and thick channel network sections Save material, Decrease reduce the cycle Reduce part manufacturing time, and warpage clamp cost by End Goa
Slide 9: Typical Installation Process
Typical Installation Process 1. Initial meeting to assess customer needs 2. Consultation with technical experts to determine GAIM feasibility based on injection goals 3. Collaboration between Air Products, equipment manufacturer, and customer to optimize process conditions, nitrogen supply and tooli
Slide 10: Implementation Through Optimization
Implementation Through Optimization We match Nitrogen for your process needs Tooling with the supply capabilities of Air Products and the equipment vendor Required to develop the Operating best and most Mold Pattern economic Pressure solution for you. 10 Air Products Internal Use Only
Slide 11: System Process Flow Diagram with Typical Scope Split
System Process Flow Diagram with Typical Scope Split Air Products Nitrogen Supply Skid Partner’s Control Module and Process Integration Liquid Nitrogen Vaporization and pressure Supply increase Customer’s Process options depending on needs and optimal supply 11 10/29/2018 Air Products Internal Use O
Slide 12: Supply Mode Options
Supply Mode Options Cylinders Microbulk Liquid Bulk On-Site On-Site Generation - Generation – Membranes Pressure Swing Adsorption (PSA) Increasing Volume Usage 12 Air Products Internal Use Only
Slide 13: Supply Mode Options
Supply Mode Options Outside Customer’s Walls Inside Customer’s Walls Gas Controller and Pressure Boost Air Products’ Cryogenic Vaporizer Pump Gas Controller Molding and Full Machine Compressor Nitrogen Supply Vaporizer 13 Air Products Internal Use Only
Slide 14: System Scope Split
System Scope Split Customer Air Products GAIM Partner • Determine optimal • Determine injection • Define Process nitrogen compression feasibility based on Needs tooling pressure • Install piping inside • Design controls • Determine low cost battery limits (*) supply mode scheme with nitrogen • Provi
Slide 15: Why Air Products?
Why Air Products? Patented Cryogenic Industry Leading Collaborative Pumping Computational Supply Approach to Technology Modeling Center Drive Value • Higher efficiency than • First in industry – • Best in class research typical cryogenic started in 1985 experts and engineers pumps • World class, use
Slide 16: Patented Cryogenic Pumps
Patented Cryogenic Pumps ● Standard pump design adapted to increase pumping efficiency over industry norms - Average of 5% savings ● All pumps reworked by Air Products dedicated cryogenic machinery facility ● Available in several standard sizes 16 Air Products Internal Use Only
Slide 17: Computational Modeling Center
Computational Modeling Center ● Air Products is a leader in the industrial gas industry in Computational Fluid Dynamic (CFD) modeling - First use in 1985 - One of the first industrial customers of Fluent ● Air Products accelerate CFD application to support R&D, engineering, and customer support in l
Slide 18: Frequently Asked Questions
Frequently Asked Questions ● What kinds of materials work with GAIM? - Virtually all thermoplastics with some limitations with heat sensitive materials ● Do I need a license? - No, this requirement went away many years ago. If a vendor is asking for a license, you’re working with the wrong vendor. ●
Slide 19: Thank you… tell me more
Thank you… tell me more Air Products Internal Use Only 19
Slide 20: Successful Applications in Air Products…
Successful Applications in Air Products… Glass furnace Rotary furnace Ladle preheat Cupola Inerting in powder transport Biomass storage Blast furnace Sinter hardening Cryogrinder Cryo cooling Air Products Internal Use
Slide 21: Air Products High Pressure Pumps LIN/LAR
Air Products High Pressure Pumps LIN/LAR Mini-Cryo Pump (MCP) ACD - SGV-1 / SGV-2 Pump (SGV) ● MAWP = 3000 psig(207bar) ● Multiple models ● Flow = 5000 scfh ● MAWP = 6,000 psig(414bar) ● Max monthly volume = 1MM/ month ● Flow = 45,000 scfh ● Designed for continuous duty Cryostar PD-3000 Pump (CVI) ●
Slide 22: Example of Design Optimization
Example of Design Optimization Extent of gas Polymer skin Volumetric penetration thickness fill time High thermal diffusivity longer thicker longer Low thermal diffusivity shorter thinner shorter Material Properties High viscosity longer thicker longer Low viscosity shorter thinner shorter Higher ga