We see Monopolistic competition in market around us, that is renowned brand competitors providing similar products which is differentiated and hallmarked on the basis of their characteristics which goes beyond simple cost. This type of market is widespread around the whole world for products at a wide range of price points.
The same competition also flows in Car World. All the competitors are daily trying to get to something which makes them prior in the market than others. Being in the same competition, automakers like Ford and Cadillac are trying to get a new revolution which is to make the car parts lighter in weight, so it becomes lighter and swifter as compared to other competitors. The solution which they have put forward is “to add bubbles”, this will make the industrial-grade plastic parts of car lighter and will maintain its strength same as before.
This technology was introduced by MIT about two decade back and developments were on its verge. Now it has been commercialized by Trexel Inc. The technology which will make the material/product lighter is by adding bubble-infused plastic, MuCell Plastic, Microcellular Foaming Technology. It’s an innovation which facilitates to reduce raw material consumption whilst producing strong and lightweight products.
How is it done?
There are four steps through which MuCell is brought into effect:
1.Gas Dissolution: A supercritical fluid (SCF) of an atmospheric gas Carbon Monoxide and Nitrogen (CO and N) is injected into the polymer through injectors barrel to form installed in the single-phase solution. The SCF delivery system, screw and injectors are specifically designed to facilitate the rapid dissolution of the SCF in the polymer.
2.Nucleation: A large number of nucleation sites (orders of magnitude more than with conventional foaming processes) are formed throughout the polymer during the molding process. A substantial and rapid pressure drop is necessary to create the large number of uniform sites.
3.Cell Growth: Cell growth is controlled by processing conditions. Precise control of pressure and temperature is achieved through specifically-designed machine controlled hardware and software.
4.Shaping: After injection into the mold, part shape is controlled by the mold design. Although mold modifications are not required, in some cases modifications will optimize the benefits of MuCell.
Microscopic Representation : Honeycomb structure of the MuCell plastic
How MuCell plastic does not make the material weak?
Many products have been converted from larger machines to smaller MuCell equipped machines utilizing the drastic reductions in clamp tonnage. Most notably, the process is being applied in applications never before thought possible with other conventional technologies. The gas nucleates cells during injection and allows the thin wall cavities to be filled with reduced pressure and with reduced clamp tonnage. This permits additional thin walling. The microcells then replace their equivalent volume of plastic, resulting in a cumulative reduction of up to 10% in packaging weight without any perceptible difference in the final plastic quality. Hence the material will be strong as before with lighter weight and new look.
A few benefits of MuCell Plastic are:
1.It’s major weight saving backup (upto50%).
2.Reduces the material viscosity.
3.The processing temperature is significantly reduced.
4.Reduction of 30-50% in hydraulic injection pressure.
5.Minimized cycle time.
In addition to the raw material savings that comes with weight reduction, MuCell plastic can also give designers more latitude with material choice. Because MuCell plastic cuts melt viscosity and reduces warpage, designers may be able to substitute a lower-grade material for one in higher-grade.
Levi Kishbaugh, VP of Engineering at Trexel says “Sustainability initiative. Automakers like Ford have sampled the MuCell process over the past decade and have achieved good results, and now they are taking the next steps toward widespread adoption. When MuCell is incorporated into part design and mechanical tolerances from the get-go (rather than applied downstream in the process), even greater weight reductions can be achieved while maintaining part strength 20% or even more in many cases.”
MuCell technology inspired by the Aero bar will first appear in Ford vehicle engine covers
To enhance its importance in the automobile industry, Ford hopes to use the MuCell plastics in its entire vehicle range by year 2020. The plans of injecting MuCell in chief plastic parts will help Ford to reduce 10% weight of its total car weights. Introducing MuCell in its production line will touch Ford’s mapped goals by competing against average cars in market which will be 125 to 325 kg heavier than its cars series. With Ford, brands like Cadillac are also in the same long race.
As we move forward we are exploring and capturing new heights, heights in all the fields from sharp needle to huge airplanes. We have acquired the skill to modify ourselves to the continuous changes happening in world. Transforming ourselves into the modern and trying to be as fast as light and as updated as a lightning bolt. Well, as consumers, we would be on cloud nine to have bestest choice available.
