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This news article was originally written in Spanish. It has been automatically translated for your convenience. Reasonable efforts have been made to provide an accurate translation, however, no automated translation is perfect nor is it intended to replace a human translator. The original article in Spanish can be viewed at Ultramelt aporta beneficios al proceso de extrusión y de moldeado por inyección

Ver más artículos sobre: Special K'2004

The K-2004 presents the first findings obtained by the European partnerships in the research of the project

Ultramelt brings benefits to the process of extrusion and moulding injection

Drafting PU15/09/2004

The four associations industrial European plastics - Assocomaplast (Italy), AVEP Association Valencian business of plastics (Spain), the Danish Plastics Federation and the Association of distributors and manufacturers of machinery for polymers (United Kingdom) - have been working together with its partners in the development of an innovative process in the sector of the extrusion and molding by injection. The project, called Ultramelt, investigates the application of ultrasonic vibration to improve the fluidity of the polymer during processing by the reduction of viscosity in melt.

In addition to the four European associations of plastic, the work also supports the promoter initial DKI Plast (Denmark), and the partners who support research PEAR (United Kingdom), FHG-TEG (Germany), Aimplas (Spain) and Cesap (Italy).

In the extrusion process, carried out rheological measurements showed that reductions in viscosity by the effect of ultrasound are between 40 to 60 percent, depending on the material, without an appreciable increase in temperature.

Through material characterization tests have shown that this is achieved without variation of mechanical properties. The effect of ultrasound is not permanent and is limited to the time of the application on the polymer. Therefore, Ultramelt brings benefits to the process of extrusion of thermoplastics in saving energy, improving the performance and speed of the process.

Participation of the partners

PEAR RTD (United Kingdom): design and development of the system for injection by moulding
fhg-teg (Germany): development of ultrasound, design and manufacture of the system
Aimplas (Spain): development of tools for the study of the process rheological. Characterization of the effect of ultrasound on the material.
Cesap (Italy): training, testing, certificates, and aid to processors of plastics.

The project partners

PMMDA, United Kingdom: 85 partners representing manufacturers and distributors of machinery.
DPF, Denmark: 320 partners representing 11 industrial sectors through to plastics converters and suppliers of raw materials and machinery.
AVEP, Spain: 188 partners representing employers in the plastic.
Assocomaplast, Italy: 169 partners representing the manufacturers of machines for plastic and rubber.

It has also found that the influence of the Ultramelt process depends on the MFI of the material, the type of polymer and the conditions of the process to be used

Ultramelt has also been applied to the process of molding by injection. Using a system prototype, it was discovered that you can be achieved to increase the length of the plastic flow up to 200 per cent for certain materials, using the same injection conditions. Applying ultrasound decreases the viscosity of the melt and therefore required during the filling phase pressure drops. Using the same size of piece with the same conditions in the process, you can reduce the time of injection for the molding of a PP by 40 per cent (from 1'3 to 0'7 seconds) reaching the same pressure of injection.

It has also found that the influence of the Ultramelt process depends on the MFI (index of fluidity) of the material, the type of polymer and the conditions of the process being used. The greatest increase in the flow was achieved with a low MFI, degree 3.0 PP.

How does it work?

The hypothesis that has gained greater strength is ultrasound to increase the degree of alignment of the molecules of the polymer, resulting in a temporary reduction of viscosity.

Ultramelt process used ultrasonic vibration of the novel and original way, for which patent applications were filed in 2002.

Currently the work is going to continue doing new tests on a more extensive range of PP with different grades (MFI) and other materials. The project will also investigate the effect of Ultramelt in the reduction of the thickness of wall of the pieces that, on the basis of previous studies, should achieve a reduction of up to 33 percent. Case studies are also being developed to assess the potential energy savings that will result in the application of Ultramelt.

Related Companies or Entities

AIMPLAS - Instituto Tecnológico del Plástico

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Asociación Valenciana de Empresarios de Plástico

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