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The MuCell® Injection Molding Process involves the highly controlled use of gas in its supercritical state (SCF) to created millions of micron-sized voids in thin wall molded parts (less than 3mm). With the correct equipment configuration, mold design, and processing conditions these microcellular voids are relatively uniform in size and distribution.
The voids are created or nucleated as a result of homogeneous nucleation that occurs when a single-phase solution of polymer and gas (commonly nitrogen, but occasionally carbon dioxide) passes through the injection gate into the mold.
The single-phase solution is created through the operation of a conventional injection molding machine which has been modified to allow the creation of a single-phase solution. The key modifications to the system involve the use of a precision SCF delivery system to deliver SCF to special injectors based on mass flow metering principles. The SCF is then injected into the barrel where it is mixed with the polymer via a specially designed screw. A shut off nozzle maintains the single phase solution while the injection molding screw maintains sufficient back pressure at all times to prevent premature foaming or the loss of pressure which would allow the single phase solution to return to the two phase solution.
Trexel has recently published a comprehensive MuCell® Process Guide in English, Chinese, Japanese, and German which explains in step by step detail how to apply the MuCell® process in the manufacture of MuCell® Injection Molded components. This 25 page processing handbook covers all aspects of the process from set-up to troubleshooting to optimizing results. It is primarily useful to companies who are manufacturing or are planning to manufacture parts using the MuCell® Injection Molding Process. Please contact Trexel for a copy of this publication.
Special topics of technical relevance are available at the following links.
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