Beaumont technologies inc.

Erie, PA, United States

Beaumont technologies inc.

Erie, PA, United States

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Li Q.,Lehigh University | Choo S.R.,Lehigh University | Coulter J.P.,Lehigh University | Beaumont J.P.,Beaumont Technologies Inc. | Rhoades A.M.,Pennsylvania State University
Annual Technical Conference - ANTEC, Conference Proceedings | Year: 2016

Since the beginning of injection molding industry development, multi-cavity molding has been widely utilized to increase manufacturing efficiency, save time and reduce costs. As a result, geometrically balanced mold cavities and runner systems have become industry standards for injection molding. Some seemingly balanced designs, however, still provide imbalanced cavity filling results. The reason for the imbalanced filling is due to the shearing between the lamellae of the molten polymer as it is injected through the runner system and into the mold cavities. The current investigation includes visual studies of how the shearing of the polymer through the runner systems affects the mold filling in real time. In order to develop a deeper understanding of the shear induced imbalances in injection molding, a custom built mold incorporating transparent mold inserts and runner systems was used. Polymers were injection molded into different types of cavities and the cavity filling was documented in real time via a high-speed camera. With this study, there is a potential to find and/or verify methods to mitigate the non-uniform behavior of molten polymers undergoing shear thinning or shear heating, especially since the imbalances have the potential to alter properties of the finished products.


Li Q.,Lehigh University | Coulter J.P.,Lehigh University | Beaumont J.P.,Beaumont Technologies Inc. | Rhoades A.M.,Pennsylvania State University
Annual Technical Conference - ANTEC, Conference Proceedings | Year: 2015

Runner based shear imbalance has been existed since the beginning of the related polymer injection molding development. The major phenomenon of the shear imbalance is the non-unique filling results in the molding cavities, even if the cavities are balanced in space and position. Researchers have been studying the shear imbalance problems, such as shrinkage or warpage, and the associated solutions for years. However, there is not such a solution that could be universally accepted by all industries or research academies. In some previous studies, a novel technology, Melt Rotation Technology, has been studied and developed theoretically and experimentally, providing persuasive evidence that the melt flow shear gradients developed in the runner system during traditional injection molding process is mainly responsible for the imbalance filling results, and Melt Rotation Technology was able to overcome the shear induced problem and modify the thermal, physical or mechanical properties of the molded specimens. [1] In the current study, polymer samples molded with and without Melt Rotation Technology were tested and compared logically. Specimens from higher shear melt flow regions exhibited higher crystallinity as well as higher melting temperatures due to the localized shear rate variation. New molding trials were implemented and more experimental results have been found to support the effectiveness of Melt Rotation Technology.


Li Q.,Lehigh University | Coulter J.P.,Lehigh University | Beaumont J.P.,Beaumont Technologies Inc. | Rhoades A.M.,Pennsylvania State University
Annual Technical Conference - ANTEC, Conference Proceedings | Year: 2014

For some time now the effects of runner-based shear imbalances on melt flows during polymer molding processes have been studied and found to be problematic, even in cases where mold cavities are naturally balanced as traditionally defined. In such instances, melt rotation technology has been applied on many occasions to accommodate resulting cavity filling imbalances as well as shrinkage and warpage issues. In the present study, this approach was taken a step further with the goal of exploring affiliated product quality variations that exist as an extension of the imbalanced polymer melt flow problem. Molding trials were conducted with and without melt rotation using several types of polymers, and the resultant effects on final product physical, thermal and mechanical properties were explored. When this was done, it was found that important product quality parameters such as crystallinity and tensile modulus can vary significantly throughout conventionally molded products and be dramatically altered by the implementation of melt rotation technology. Specimens taken from product regions associated with higher melt flow shear levels exhibited higher crystallinity levels as well as higher tensile moduli. This supports the concept of melt rotation adoption for a broader range of problems extending far beyond cavity fill balancing alone. Copyright © (2014) by the Society of Plastics Engineers All rights reserved.


Beaumont J.,Beaumont Technologies Inc.
Plastics Technology | Year: 2012

Beaumont Technologies has developed the ''Therma-flo' Moldometer in response to a growing need for plastic melt characterization for injection molding. This new method characterizes the injection moldability of a plastic material through a wide range of mold geometries and processes using an actual injection molding machine. It significantly improves on the ability of a mold or part designer to make informed decisions when selecting or designing for a given plastic material. It also helps the injection molder to determine whether a particular machine will be capable of filling that mold. It is necessary to consider the application and the manufacturability requirements of a material during the plastic material selection process. One of the more critical considerations when selecting a plastic material for manufacturability involves trying to determine how it will flow in an injection mold.


Hoffman D.,Beaumont Technologies Inc. | Beaumont J.,Beaumont Technologies Inc.
Plastics Technology | Year: 2013

Injection molding process methodologies have evolved over a period of time from a seat-of-the-pants process to a more structured approach. One of the important process parameters to establish and record for any injection molded part is its injection or fill time. Fill time is an indication of how fast the plastic is injected into the mold. Fill time affects how much shear heating and shear thinning the plastic experiences, which affect the material's viscosity, the pressure and temperature of the plastic inside the cavities, and the overall part quality. An established fill time for a given mold needs to live with the mold forever and should be allowed to vary only slightly. Molders use several methods to establish a fill time, some of which start with evaluating the fill time used on similar parts and molds and mold-filling simulation.


Hoffman D.A.,Beaumont technologies inc.
Plastics Engineering | Year: 2014

Depending on the wall thickness, the material being molded, the process conditions, the cavity orientation, gate location, and a few other factors, gravity may finally have a chance to work its magic on the thick walled plastic parts, the first example will be the original mold that John Beaumont designed and built to study the effect of shear on material properties and the resulting mold filling variations. A second gravity example comes from an eight-cavity mold used to produce thick-walled screwdriver handles. There was more plastic at the bottom than at the top of the four bottom cavities. Again the plastic came out of the gate and had no steel around it to flow against and stick to. Simulation was run again with the new gravity orientation, and the results correlated well with the actual short shots.


Hoffman D.A.,Beaumont Technologies Inc.
Plastics Engineering | Year: 2015

Experts suggest that processors need to apply an understanding of plastic flow when marking mold cavities to get more than cavity IDs from given cavity IDs. Cavity identification markings (cavity IDs) are used to distinguish one cavity from another. This is important to help provide traceability for things, such as quality, mold maintenance issues, and short shot imbalance data. The first important point that needs to be considers concerns the location of the ID markings within the cavity itself. a second important point to make is to avoid putting cavity IDs on ejector pins.


Hoffman D.A.,Beaumont Technologies Inc.
Plastics Engineering | Year: 2015

As people begin to understand more about plastic flow and the variables in the pressure drop equation, they begin to understand how small differences can have a big impact on the molding process and part quality. Many times those small differences are found in the melt delivery system, whether it be a hot runner or cold runner or a combination of the two. When designing special features into the molds the designer must design puller pins such that they do not restrict the main flow path. Where appropriate, he must add the particular feature to both sides of the sprue and at each side of the preceding intersection.


Patent
Beaumont Technologies Inc. | Date: 2013-04-01

A material characterization system and method for quantifying the characteristics of a flowing thermoplastic material is presented. The system comprises a tool comprising first and second tool halves, a plurality of flowing material characterization channels, and a feed runner. The tool is at a temperature that causes phase changes from fluid to solid in at least a portion of the characterized material and enables solidification of the material in the flowing material characterization channels. The feed runner is connectable to a single flowing material characterization channel. The tool is adjustable to disconnect the feed runner from one flowing material characterization channel and connect it to different flowing material characterization channels. A sensor quantifies the characteristics of the material under different flow conditions. The method comprises measuring the material characteristics as it flows through the flowing material characterization channel at multiple flow rates and repeating measurements for different flowing material characterization channels.

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