Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide

Antje Birkholz, Martin Tschiersky, Johannes Wortberg

Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademic

1 Citation (Scopus)
128 Downloads (Pure)


For the installation of a fuel cell stack to convert chemical energy into electricity it is common to apply bipolar plates to separate and distribute reaction gases and cooling agents. For reducing manufacturing costs of bipolar plates a fully automated injection molding process is examined. The high performance thermoplastic matrix material, polyphenylene sulfide (PPS), defies against the chemical setting and the operation temperature up to 200 °C. To adjust also high electrical and thermal conductivity, PPS is highly filled with various carbon fillers up to an amount of 65 percentage by volume. In the first step two different structural plates (one-sided) with three different gate heights and molds are designed according to the characteristics of a bipolar plate. To cope with the approach that this plate should be producible on standard injection molding machines with variothermal mold temperature control, injection molding simulation is used. Additionally, the simulation should allow to formulate a quality prediction model, which is transferrable to bipolar plates. Obviously, the basis for a precise simulation output is an accurate description of the material properties and behavior of the highly filled compound. This, the design of the structural plate and mold and the optimization via simulation is presented, as well. The influence of the injection molding process parameters, e.g. injection time, cycle times, packing pressure, mold temperature, and melt temperature on the form filling have been simulated to determine optimal process conditions. With the aid of the simulation and the variothermal mold temperature control it was possible to reduce the required melt temperature below the decomposition temperature of PPS. Thereby, hazardous decomposition products as hydrogen sulfide are obviated. Thus, the health of the processor, the longevity of the injection molding machine as well as the material and product properties can be protected.
Original languageEnglish
Title of host publicationPROCEEDINGS OF PPS-30: The 30th International Conference of the Polymer Processing Society – Conference Papers
EditorsSadhan C. Jana
PublisherAmerican Institute of Physics
Number of pages5
ISBN (Electronic)978-0-7354-1309-2
Publication statusPublished - 22 May 2015
Externally publishedYes
Event30th International Conference of the Polymer Processing Society 2014 - Cleveland, United States
Duration: 6 Jun 201412 Jun 2014
Conference number: 30

Publication series

NameAIP conference proceedings


Conference30th International Conference of the Polymer Processing Society 2014
Abbreviated titlePPS 2014
Country/TerritoryUnited States


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