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The document discusses blow molding, a polymer processing technique used to produce hollow plastic parts. It covers topics such as examples of blow molded products, general principles and equipment, process parameters, and factors that influence die swell.

Examples of products made through blow molding mentioned include automotive parts, bottles, storage vessels, films, and sporting goods.

General principles and equipment discussed include parison formation, mold closing and air introduction to expand the parison, mold opening, and part trimming. Equipment used includes an extruder, mold, and clamping mechanism.

EMA 4666C - Polymer Processing Blow Molding Operations

Dr. Anthony Brennan University of Florida Department of Materials Science & Engineering
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Agenda
Introduction
Examples of blow molded products General Principles Equipment Design

Process Parameters
Troutonian Viscosity Flow Properties
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Blow Molded Products

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Blow Molding Examples


Automotive Bottles Storage Vessels Films Sporting Goods
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Rubber Parts Automotive

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Co-extrusion Blow Molding of Thermoplastic Elastomers

Phone: (573) 221-8933 Fax: (573) 221-7144 www.buckhornrubber.com

Capabilities Overview
3-D Blow Molding using XY Technology Produces complex parts with minimal flash Dual materials are introduced to create hardsoft-hard products for flexibility and high performance Secondary operations are performed by robotic technology Reduced cycle times compared to traditional blow molding

XY Manufacturing System

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Total System Cost Reduction


Up to 50% reduction in tool lead time and tool cost. Up to 70% reduction in system weight. Overall piece price reduction. Complex system designs. Reduction in number of system components. Buckhorn will design a system based on your parameters. Data transfer capabilities are available. A variety of plastic material formulations are available to select the best, cost effective material for your application.

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XY Blow Molding Process Parts are produced using blow molding process on an XY plane for complex geometries

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XY Blow Molding Cycle


Parison enters mold Mold is closed, air introduced

Mold opens

Part is trimmed

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Features & Benefits Dual durometer Part consolidation Seamless parts Produces complex parts with reduced flash Parts incorporate both strong, rigid and soft, flexible features

Inserts in Blow Molded Parts

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Secondary Operations

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Parts Trimming
Produces consistently trimmed/drilled parts Quick cycle time

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Blow Molding Thermoplastic Elastomers

Thermoplastic elastomers for hard-soft-hard applications A wide range of fillers are available for improving material properties over different temperature ranges 8/24/2012
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Blow Molding Material

Polypropylene Polyethylene (High or low density) Polyamides (Nylons) Santoprene Geolast

Blow Molded Products


Air Intake Hoses Air Resonators Steering Column Cover Gas Intake Tubes Automotive Air Ducts Fluid Reservoirs HVAC Ducts
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Applications
OEM Truck Agriculture Lawn & Garden Marine Construction Equipment Recreational Vehicles Automotive Industrial Gen-Set

Tooling
High-performance machined aluminum or cast aluminum production tooling

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Prototype Tooling
High-performance cast aluminum

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Lead Times

Rubber Injection Molded Parts

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Blow Molded Insulated Coolers

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Insert Blow Molded Tanks

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Blow Molding Process Equipment

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Bottles Bottles
http://www.uniloymilacron.com/u nirecip.htm

Injection Blow
IBS 122 Injection Blow

Completely refurbished 2.5 inch screw 250 gram shot size (HDPE)
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Injection Stretch Blow


U750-120 (1) & U750-130 (2) Injection Stretch-Blow for PET - WIDEMOUTH Single-stage, 4-station process (conditioning) 120-ton or 130-ton injection 2 to 10 cavities Accepts common tooling Movie of Process:
http://engr.bd.psu.edu/pkoch/plasticdesign/Blow_Molding.htm 8/24/2012
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Extrusion Blow Molding Process

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Extrusion Blow Molding Cycle

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Continuous Blow Molding Equip


EXTRUDER

DIE H HEAD

MOLD

PARISON
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CONTINUOUS EXTRUSION BLOW MOLDING


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CBM Ram Accumulator


SHUT-OFF VALVE

RAM ACCUMULATOR

MOLD PARISON
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RAM ACCUMULATOR BLOW MOLDING MACHINE

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Extrusion Blow Molding


Jomar Continuous Extrusion Blow Moulding
http://www.jomarcorp.com/ebm_process.asp

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Parison Molding

Parisons

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Injection Blow Molding


Station 1: Injection Mold Preform (Parison) Station 2: Inflate Station 3: Strip Time: 32 bottles per cycle. 9 to 20 sec per cycle.
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DIE SWELL BEHAVIOR

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Basis for Die Swell


Die Swell Two Causes: 1. Elastic Recovery 2. Velocity Profile Change Elastic Recovery 1. Chains diffuse from elongated to random coil. 2. Orientation dependent upon processing conditions

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Parison Morphology

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Die Swell Behavior: HDPE v ABS

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Influence of L/D on Die Swell

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Process Time line

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Velocity Profiles for Stress Fields

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Velocity Profiles Planar Deformation

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END OF EXAM 1 Material

Spring 2012

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Viscosity Response

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Viscosity: Temperature Response

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Effect of Blow Up Ratio

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Blow Molding Process Variables


Thermal Properties/History

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PPS DSC Profile

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Effect of Rapid Quench - Xtal

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Crystallization Behavior - PPS

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Critical Factors for Blow Molding


Material Melt Strength Die Swell Impact Strength ESCR Chemical Resistance Printability
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Process High/Low Rate Planar Extension Blow Pressure Stock Temperature Mold Temperature

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Blow Molding - Films

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Trouble Shooting Guide

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References
Introduction to Physical Polymer Science, 2nd Edition, Lesley H. Sperling, Wiley Interscience (1992) ISBN 0-471-53035-2 Some figures were reproduced from: Polymer Processing Fundamentals, Tim A. Osswald (1998), Hanser/Gardner Publications, Cincinnati, OH. The Physics of Polymers, Gert Strobl (1996) Springer-Verlag, New York.

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