Applicationsofthermoformabilityanalyzer.docVIP

Applications of Thermoformability Analyzer Amit Dharia Transmit Technology Group, LLC, Irving, TX Abstract Thermoforming consistent parts depend on knowing and controlling several material and process variables, the most important being the quality of the sheet feed stock. The extruded sheet of the same material could vary in terms of polymeric contamination, thickness, thermal stresses, and amount of regrind, volatiles, color, gloss and grain. Mold material and mold temperature could also vary. Many times, effects of such variations manifest during actual thermoforming in form of tearing, wall thinning, shape distortion, fading, pinholes, and grain distortion. We illustrate use of novel equipment for rapid detection of such variables and their effects on thermoformability, sparring need for expensive plant time and material waste. Introduction Thermoforming is a process of shaping a plastic sheet heated above softening point by stretching it over or inside the mold cavity by rapid application of force. It is widely used in shaping parts with large area to weight ratio where injection molding is either not feasible or not economical. The ability of thermoplastic to thermoform primarily depends on its softening point, % crystallinity, strength and elasticity at thermoforming temperature and speed. However, the extrusion history of feedstock itself introduces wide range of variables of which processor is not aware of. Most often, source of variation is due to regrind, heat history of regrind, polymeric impurity, improper drying, volatiles, incompatible additives, improper screw design leaving unmelted pellets or poor dispersion, improper or uneven roll temperatures causing uneven thermal stresses, uneven roll speed or nip gap causing uneven thickness across the width or waves along the length. Unfortunately, processors learn of any such abnormality only while thermoforming. At present there is no standard incoming QA or QC tests other than supplier’s spec