Dow Inc. · NYSE:DOW
Dow — Proplast — K12 Midterm conference 2017
34 slides from Dow's conference presentation, May 18, 2017
Slide 1: Lightweighting Techniques for Thermoplastic Polymers
Lightweighting Techniques for Thermoplastic Polymers by Maria Rosa Contardi, Maria Teresa Scrivani K12 Midterm conference, May 18th 2017
Slide 2: Mission
Mission Proplast private R&D centre, representing the «actors» of polymer and composite materials and processing industry To know more about partner companies see: http://www.proplast.it/en-us/Members/Detail
Slide 3: Our Premises
pro@last INNOVATION POLE PLASTICS Our Premises new premises C/O Parco tecnologico - Rivalta Scrivia Acadenic traning (Pltzric Taine) Pro@last technical sees SMES pro@last cus cnguesig spelt var | Bee el cen cants Patan eet ra se Tecoogy rare ponent ap jeden pro@last basic and fundamental resoarch (p
Slide 4: Technical training
Technical training Our activities
Slide 5: EU collaborative research projects
EU collaborative research projects Improvement of the plastic packaging waste chain from a circular economy approach (H2020) Developing Novel Fire-Resistant High Performance Composites (FP7) Development of biophotonic device based on flexible light emitting textile dedicated to the monitoring and tr
Slide 6: National collaborative research projects
National collaborative research projects GreenFactory4Compo Green Factory for Composites (Regione Piemonte - Piattaforma «Smart Manufacturing») Veicoli urbani stradali su gomma ecologici, ergonomici, economici, sicuri ed interconnessi, per il trasporto di persone e/o merci (Ministero per lo sviluppo
Slide 7: Training activities
Training activities • Classes for graduated students - post University specialization degree in Polymer Science and Technology • Classes for high school graduates - injection molding - mold maintenance - CAD for plastics • Classes for people working in the plastics sector - more than 30 different th
Slide 8: Dissemination activities
Dissemination activities Seminars and conferences about new materials and new technologies Events examples: • Heat & Cool Technologies • Conductive Polymers • Technical conference on Mucell® technology • Energy management for the plastic processing industry • Polymers compounding • Scientific mouldi
Slide 9: Materials engineering
Materials engineering Tailoring of formulations vs. the final application Development of high-performance polymeric by the means of different technologies materials: (compounding, melt blending, reactor and solid state • flame retardant materials polymerisation) • nanocomposites • high stability
Slide 10: Process engineering
Process engineering • Injection molding (Heat-and-cool, Roctool®, Mucell®) • Pre-series molding • Compounding • Film extrusion • Thermoforming • Thermoplastics & thermosets composites • Metal/ceramic injection molding (MIM, CIM)
Slide 11: Product engineering
Product engineering • Development and optimization of new products Product and process engineering • Design and manufacturing of pilot molds • Rapid prototyping • Static/dynamic non linear analysis FEM structural simulations • Impact analysis • Modal/vibrations analysis • Thermoplastics injection mo
Slide 12: Lightweighting in injection molding: the MuCell technology
Lightweighting in injection molding: the MuCell® technology The two key elements of MuCell technology: 1. Lowering of the viscosity of thermoplastic resins by controlled feeding of gas (either N2 or CO2) into the melt 2. Creation of a microcellular structure in the part core by gas expansion in the
Slide 13: Lightweighting in injection molding: the MuCell technology
Lightweighting in injection molding: the MuCell® technology A single phase solution is created by injecting the SCF (super critical fluid) into the thermoplastic melt during screw recovering
Slide 14: MuCell line typical layout
Lightweighting in injection molding: the MuCell® technology MuCell line typical layout
Slide 15: Lightweighting in injection molding: the MuCell technology
Lightweighting in injection molding: the MuCell® technology Typical ‘sandwich’ structure of MuCell parts: Compact skin - Foamed core - Compact skin
Slide 16: Lightweighting in injection molding: the MuCell technology
Lightweighting in injection molding: the MuCell® technology Foaming occurs during injection into the mold . .. . . .. . . . .. . . .. . .. . . .. . .. . . . Time Time Low pressure in the mold cause SCF to form cells Cells grow until the material freezes or the mold cavity is full
Slide 17: Lightweighting in injection molding: the MuCell Process
Lightweighting in injection molding: the MuCell® Process MuCell benefits •Cavity foaming process instead of post pressure Without MuCell lower clamping force •Injection unit lower viscosity, leading to better filling behavior and lower pressures better filling behavior new part design and gate posit
Slide 18: Productivity improvement: overall cycle time reduction
Lightweighting in injection molding: the MuCell® Process Productivity improvement: overall cycle time reduction
Slide 19: Productivity improvement: reduction of hydraulic pressure
Lightweighting in injection molding: the MuCell® Process Productivity improvement: reduction of hydraulic pressure Solid MuCell® Peak pc = 1045 bar Peak pc = 448 bar Screw position Data Com Connector, PBT 30 % GF 57 % reduction in peak cavity pressure Due to viscosity reduction, less resin volum
Slide 20: Case History #1: Cam Cover
Lightweighting in injection molding: the MuCell® Process Case History #1 : Cam Cover Achieved benefits: 30% reduced machine size (350 instead of 500 ton for conventional molding) Improved cycle times, allowing for simultaneous production and assembly process Lighter part Improved flatness
Slide 21: Case History #2: Dual fan shroud
Lightweighting in injection molding: the MuCell® Process Case History #2 : Dual fan shroud Achieved benefits Typical weight reduction 7-10% Machine size reduction from 1000 tons to 500 tons Cycle time savings of 25-40% 200% improvement in fatigue resistance Cpk values improved by 50%
Slide 22: Processing: injection molding - RocTool
Processing: injection molding - RocTool Roctool Processes Advanced Heat & Cool technology for Composite and Plastic Injection molding by using electromagnetic induction allows to heat a mould in a matter of seconds. Roctool benefits • Optimal surface quality: glossy or mat, no visible weld lines • T
Slide 23: Processing: light weight extrusion - Promix
Processing: light weight extrusion - Promix Promix Solutions • In extrusion processes temperature differences in the melt are generated by the plasticizing process in the screw, melt pumps, screen changers and even by empty pipe sections. • Melt Blenders such as Promix blenders efficiently equalize
Slide 24: Processing: light weight extrusion - Promix
Processing: light weight extrusion - Promix In an empty pipe polymer melts will form a laminar profile Promix melt blenders destroy the laminar profile and create a very effective cross mixing resulting in: • Equal velocity • Equal temperature • Narrow residence time distribution • Excellent melt ho
Slide 25: Processing: light weight extrusion - Promix
Processing: light weight extrusion - Promix
Slide 26: Effective temperature homogenization
Processing: light weight extrusion - Promix Effective temperature homogenization
Slide 27: Benefits of Promix Mixing Nozzles
Processing: light weight extrusion - Promix Benefits of Promix Mixing Nozzles • Effective avoidance of color streaks • Equalized color depth / better color appearance • Saving of 20 – 30% master batch (= 1’000 to >10’000 Euro savings / year) • No brilliant spots due to homogenization of temperature
Slide 28: Promix foaming system
Processing: light weight extrusion - Promix Promix foaming system is a patented process for the production of extruded microcellular foams. Main features: • Significant weight and cost reductions • High quality microcellular foams • Density reductions of 10 to >70% • Use of the environmental friendl
Slide 29: Promix foam system with fluid injection and static mixing
Processing: light weight extrusion - Promix Promix foam system with fluid injection and static mixing and cooling modules Promix foam extrusion systems are installed downstream of the existing extruder barrel and consist of components for fluid injection, homogenization and cooling. The blowing flui
Slide 30: Advantages of physical vs. chemical foaming
Processing: light weight extrusion - Promix Advantages of physical vs. chemical foaming: • Fast amortization of investment, usually < 1 year • Higher process stability, better cell structure • Lower foam densities possible • No health risks due to chemical residues • Production waste is 100% recycla
Slide 31: Installation example
Processing: light weight extrusion - Promix Installation example
Slide 32: Case History #1: dairy products packaging
Processing: light weight extrusion - Promix Case History #1 : dairy products packaging
Slide 33: Case History #2: PP foam core pipes
Processing: light weight extrusion - Promix Case History #2 : PP foam core pipes PP foam sheet Automotive application Density 210kg/m3 (13lb/ft3) Result: • Reduction of foam density
Slide 34: Thanks for your attention
Thanks for your attention Proplast - Consorzio per la promozione della cultura plastica Strada Savonesa, 9 – 15057 Rivalta Scrivia – AL Tel: +39 0131 1859711 proplast@proplast.it www.proplast.it Form 830-046-0717