MuCell Microcellular Injection Molding Processing Technology

1 MuCellTMMicrocellular Injection Molding Processing TechnologyMuCellTMMolding TechnologyCYCLE TIME REDUCTION WEIGHT REDUCTION CLAMP TONNAGE REDUCTIONThe innovative MuCell Microcellular foam process, which was developed at the Massachusetts Institute of Technology (MIT) and Trexel, is covered by patents and patents pending in Asia, Europe and North America. The MuCell moldingtechnology is available as an option on selected new Injection Molding and structural foam Molding machines. AllMuCell-capable Injection Molding machines and structural foam machines are also capable of conventional,non-foaming can gain a competitive advantage with the MuCell process by utilizing its Processing benefits, endothermicreaction, lower viscosity and lower melt and mold temperature.

2 These benefits typically result in significant reductions in cycletime, material consumption, Injection pressure and clamp tonnage. This Microcellular foam process is unique because it canbe applied to thin-wall parts and to materials that cannot be foamed successfully with any other foaming technologies. Insummary, competitive advantages can be achieved not only in existing markets, but also in new opportunities for Injection molders originate from a breakthrough Molding Technology , offering tremendous capabilitiesnever before seen with other Molding processes.

3 MuCellTMopens new markets for innovative product design, optimizedprocessing and reduced part costs. Products manufactured using MuCell Technology are being developed and marketed ina variety of industries worldwide, including automotive, medical devices, consumer goods, electronics, food services andindustrial and consumer structural parts. Up to 60% reduction in material viscosity due to the introduction of the supercritical fluidSignificant reductions in Processing temperatures (as much as78 C, 140 F), resulting from lower viscosity30-50% reduction in hydraulic Injection pressureReductions in cycle time due to the elimination of hold pressure and time Controlled weight savings30-80% reduction in clamp tonnageElimination of sink marksInjection Molding applications of the MuCell Molding Technology have produced the following results:POLYOLEFIN TUBS.

4 THIN-WALL APPLICATION OF40 MFI POLYOLEFIN MATERIAL WALL THICKNESS- MM( ) ELIMINATION OF HOLD AND COOLING TIME FLOWRATIO= 280:1 10% MATERIAL REDUCTIONThe MuCellTMprocess Technology is being applied to a broad range ofinjection molded thermoplastic materials and applications. Molders arecurrently taking advantage of the unique process benefits that MuCellprovides. The applications that have been selected take advantage of thecontrolled weight savings and significant reductions in cycle time. Manyproducts have been converted from larger machines to smaller MuCellequipped machines utilizing the drastic reductions in clamp tonnage.

5 Mostnotably, the process is being applied in applications never before thoughtpossible with other conventional and unfilled materials such as nylon (PA), polycarbonate (PC),polypropylene (PP), polycarbonate/acrylonitrile butadiene styrene (PC/ABS),polystyrene (PS), acetal (POM), polyethylene (PE), high-temperaturesulfones, and TPE s, ( Santoprene and Kraton) have been : PA 6/6 - 33% GLASS-FILLED 66% COOLING REDUCTION CONTROLLED WEIGHT REDUCTIONS OF5, 10, 15, 20% CLAMP TONNAGE REDUCTION FROM150-TONS TO40-TONSHVAC DOOR: PA 6/6 - 40% GLASS-FILLED 30% CYCLE TIME REDUCTION EXCELLENT DIMENSIONAL STABILITY CLAMP TONNAGE REDUCTIONFROM200-TONS TO30-TONSMuCellTMTechnology Applications ACETALHIGHWEARCOMPONENTS: WEIGHT REDUCTIONS UP TO40% 20% CYCLE TIME REDUCTION CLAMP TONNAGE REDUCTION FROM150-TONS TO40-TONS ABILITY TO MOLD DIFFICULT TO FLOW MATERIALSAIRDISTRIBUTIONHOUSING: FILLED POLYPROPYLENE LARGE COMPLEX MOLD 10% WEIGHT REDUCTION 20% CYCLE TIME REDUCTIONAUTOMOTIVETRIM.

6 PP ORPC/ABS IN-MOLD DECORATION 28% Injection PRESSURE REDUCTION MELT PROCESS TEMPERATURE REDUCTION IMPROVED FABRIC/LAMINATION QUALITY ELIMINATION OF SINK MARKSFANMOTORHOUSING: 25% TALC-FILLED POLYPROPYLENE COPOLYMER 15% WEIGHT REDUCTION IN THIN COMPLEX SHAPES ELIMINATION OF SINK MARKS ELIMINATION OF HOLD PRESSURE AND TIMEFUSEBOX: 22% MICA-FILLEDPOLYPROPYLENE COPOLYMER 17-20% WEIGHT REDUCTION IN THREE DIMENSIONALPRODUCTS WITH VARIED WALL THICKNESS DOWN ( ) LIVING HINGE ELIMINATION OF SINK MARKSMEDICALHANDLES: PC ANDPOLYSULFONE UPTO30% WEIGHT REDUCTION 50% CYCLE TIME REDUCTION CLAMP TONNAGE REDUCTION FROM120-TONS TO15-TONS ABILITY TO MOLD DIFFICULT TOFLOW MATERIALSA dapting the MuCell process Injection Molding requires the following changes or additions:A supercritical fluid (SCF) of an atmospheric gas (CO and N ) is injected into the polymer through injectors installedin the barrel to form a single-phase solution.

7 The SCF delivery system, screw and injectors are specificallydesigned to facilitate the rapid dissolution of the SCF in the growth is controlled by Processing conditions. Precise control of pressure and temperature is achieved throughspecifically-designed machine controlled hardware and large number of nucleation sites (orders of magnitude more than with conventional foaming processes) areformed throughout the polymer during the Molding process. A substantial and rapid pressure drop is necessary tocreate the large number of uniform Technology GROWTHA fter Injection into the mold, part shape is controlled by the mold design.

8 Although mold modifications are notrequired, in some cases modifications will optimize the benefits of SCF metering system with sufficient capacity to deliver the SCF blowing agent to the screw at the rate andpressure required for the MuCell process. (Trexel s Equipment Division supplies properly-configured pumpsystems for SCF delivery and other proprietary components to licensees)A Trexel-designed screw for creating a single-phase solution of the SCF blowing agent. (The screw designallows for both solid and MuCell materials to be processed)

9 Minor modifications to software, system hardware and hydraulics to create and maintain the uniformity of thesingle-phase solution throughout the Injection Molding Machine RequirementsMuCellTMMicrocellular Process22 SCFportsSCF gas unit supplied by TrexelMuCell screw and barrel Melt pressure transducersAir-cooled heater bandsMinor software and hydraulic changesMuCell Screw and BarrelBarrel modificationsMuCell SCF injectorMuCell SCF metering systemMinor software and hydraulic changesEquipment ModificationsShut-offnozzle49 x 24 x (125cm x 61cm x 156cm)(See Fig )Equipment can operate in both solidand MuCell ,000100,000150,000200,000250,000300,0003 50,000400,000 Polyolefin Tub (PP)Fan Motor Housing (PP)Air Distribution Housing (PP)Child Safety Gate Cover (PP)Air Intake Manifold Gasket (PA)Mirror Bracket (PA)HVAC Door (PA)HVAC Blend Door (PA)Latch Cover (PA)Medical Handle (PC)Spool (ABS)High Wear Component (Acetal)Application (Material)Savings/ (Years)Material SavingsCycle Time SavingsPaybackSavings and PaybacksMuCellTMTechnology Cost Savings Where do potential cost savings come from?

10 Areas of Potential SavingsView right axis for PaybackCYCLETIMEMATERIALREDUCTIONELIMINA TION OFCBA COSTSREDUCTION INTOOLINGCOSTSREDUCTION ININITIALINVESTMENTCOLORANTREDUCTIONENER GYCONSUMPTIONI mplementing MuCellTMTechnology CONTACT A LICENSED OEM Injection Molding EQUIPMENT SUPPLIER ANDTREXEL FOR HARDWARE AND LICENSE QUOTATIONS. OBTAIN AMUCELL END USER LICENSE AGREEMENT FROMTREXEL, GRANTINGUSER RIGHTS TO MAKE, USE AND SELL Microcellular FOAM PRODUCTS. For a list of licensed OEM machine suppliers, please refer to our website or contact us provides the MuCell license to end users on a machine-by-machine basisThe machine license is paid annually for seven years, after which it is fully paid and irrevocable The annual license fee is determined by:Machine size (measured in clamp tonnage)Resin type (either restricted: commodity type resins such as PP, PE, and PS, or unrestricted: all resin types)STEP1:STEP2: MuCell is a trademark of Trexel, Inc.