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

Antje Birkholz; Martin  Tschiersky; Johannes Wortberg

doi:10.1063/1.4918417

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 proceeding › Conference contribution › Academic

1 Citation (Scopus)

100 Downloads (Pure)

Abstract

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 language	English
Title of host publication	PROCEEDINGS OF PPS-30: The 30th International Conference of the Polymer Processing Society – Conference Papers
Editors	Sadhan C. Jana
Publisher	American Institute of Physics
Number of pages	5
Volume	1664
ISBN (Electronic)	978-0-7354-1309-2
DOIs	https://doi.org/10.1063/1.4918417
Publication status	Published - 22 May 2015
Externally published	Yes
Event	30th International Conference of the Polymer Processing Society 2014 - Cleveland, United States Duration: 6 Jun 2014 → 12 Jun 2014 Conference number: 30

Publication series

Name	AIP conference proceedings
Volume	1664

Conference

Conference	30th International Conference of the Polymer Processing Society 2014
Abbreviated title	PPS 2014
Country/Territory	United States
City	Cleveland
Period	6/06/14 → 12/06/14

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10.1063/1.4918417

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Birkholz, A., Tschiersky, M., & Wortberg, J. (2015). Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide. In S. C. Jana (Ed.), PROCEEDINGS OF PPS-30: The 30th International Conference of the Polymer Processing Society – Conference Papers (Vol. 1664). [050013] (AIP conference proceedings; Vol. 1664). American Institute of Physics. https://doi.org/10.1063/1.4918417

Birkholz, Antje ; Tschiersky, Martin ; Wortberg, Johannes. / Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide. PROCEEDINGS OF PPS-30: The 30th International Conference of the Polymer Processing Society – Conference Papers. editor / Sadhan C. Jana. Vol. 1664 American Institute of Physics, 2015. (AIP conference proceedings).

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title = "Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide",

abstract = "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.",

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Birkholz, A, Tschiersky, M & Wortberg, J 2015, Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide. in SC Jana (ed.), PROCEEDINGS OF PPS-30: The 30th International Conference of the Polymer Processing Society – Conference Papers. vol. 1664, 050013, AIP conference proceedings, vol. 1664, American Institute of Physics, 30th International Conference of the Polymer Processing Society 2014, Cleveland, Ohio, United States, 6/06/14. https://doi.org/10.1063/1.4918417

Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide. / Birkholz, Antje; Tschiersky, Martin ; Wortberg, Johannes.

PROCEEDINGS OF PPS-30: The 30th International Conference of the Polymer Processing Society – Conference Papers. ed. / Sadhan C. Jana. Vol. 1664 American Institute of Physics, 2015. 050013 (AIP conference proceedings; Vol. 1664).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › Academic

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T1 - Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide

AU - Birkholz, Antje

AU - Tschiersky, Martin

AU - Wortberg, Johannes

N1 - Conference code: 30

PY - 2015/5/22

Y1 - 2015/5/22

N2 - 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.

AB - 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.

U2 - 10.1063/1.4918417

DO - 10.1063/1.4918417

M3 - Conference contribution

VL - 1664

T3 - AIP conference proceedings

BT - PROCEEDINGS OF PPS-30: The 30th International Conference of the Polymer Processing Society – Conference Papers

A2 - Jana, Sadhan C.

PB - American Institute of Physics

T2 - 30th International Conference of the Polymer Processing Society 2014

Y2 - 6 June 2014 through 12 June 2014

ER -

Birkholz A, Tschiersky M, Wortberg J. Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide. In Jana SC, editor, PROCEEDINGS OF PPS-30: The 30th International Conference of the Polymer Processing Society – Conference Papers. Vol. 1664. American Institute of Physics. 2015. 050013. (AIP conference proceedings). doi: 10.1063/1.4918417

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

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