MuCell system advantages for new injection molding machine

Chen Hsong and Trexel form partnership to introduce the 98-Ai 500 injection molding machine which includes the new series III MuCell system.

Chen Hsong and Trexel have announced the formation of a partnership to introduce Chen Hsong’s JM98-Ai/500-MuCell injection molding machine which includes Trexel’s New Series III MuCell* System.

Stephen Chung, Executive Director of Chen Hsong said, “This partnership between our two companies is designed to make the MuCell Process available to Chinese and other molders on our cost-effective machines. This is one part of Chen Hsong’s continuous drive to bring new technology and solution to our customers. We have evaluated the MuCell Technology for a couple of years and confirmed the value it delivers. We have also seen the growing acceptance of the technology in China as well as the worldwide market.”

Patrick Tong, General Manager of Asia for Trexel said, “We believe that the availability of a standard upgrade package on Chen Hsong’s injection molding machine will find wide application as a cost-effective solution used across numerous industries. It marks the first application of the MuCell System with a top tier injection molding system from China. Combined with the new low cost Series III System, molders who use a smaller machine for precision molding applications will also be able to take advantage of the MuCell Process.”

Trexel and Chen Hsong officials predict that the new Chen Hsong and Trexel technology combination will be attractive to both new users, as well as to the existing Chen Hsong user who needs dimensional stability on thin wall parts or who would like to upgrade their molding capability with MuCell technology.

In addition, Chen Hsong officials suggest that many companies currently seek dimensionally stable parts but until now did not have the option of a lower cost platform, and would find the Chen Hsong/Trexel combination particularly attractive.

Industrial trials conducted to date suggest that users of the new system will see significant improvements in several key quality and performance measures, including a 50-90% improvement in dimensional stability, along with 15% - 30% reductions in cycle time, 30% - 80% reductions in clamping force, plus expected savings in material usage of 6% - 12%, depending on the application and material used.

During the K-2007 exhibition, the JM98-Ai/500-MuCell injection molding machine including Trexel’s new Series III Mucell system will mold parts using Rhodia TECHNYL** XCel** polyamide, which will demonstrate the ability to produce foamed parts with excellent surface appearance when using Trexel’s MuCell technology.

The Ai/500 series of injection molding machines features the SPS 3300 advanced Computer Controller. Linear guide rails and dual cylinders ensure perfect balance and alignment during the

crucial injection process, enabling injection speeds up to 500 mm/s. The Ai/500 series also includes next-generation Ai energy-saving technology, which industrial trials suggest will reduce in-service electricity consumption by up to 45%. The Ai/500 series also integrates completely with Chen Hsong’s iChen System and iChen system for wireless shop-floor networking.

The Series III features the world’s first all-electric discontinuous dosing system for microcellular foaming. The Series III SCF System uses a unique and patented pulse dosing technology to provide accurate and repeatable discontinuous dosing for MuCell microcellular foam production.

A key design feature of the Series III MuCell system is that gas compression is accomplished with an electric drive motor instead of air driven pumps. Trexel projects this will help to reduce the required maintenance activities by 50% compared to the Series II MuCell system. In addition there is almost no in-service demand on shop air (.05 Scfm @ 65 psi versus Series II requirements at start-up of 90 Scfm @ 80 psi).

The Series III SCF system is designed to take a supply of nitrogen from a high pressure cylinder and provide a precise dose of nitrogen at a chosen set point. The nitrogen supply is fed to a gas piston. An electric drive motor is attached to the gas piston, compressing the nitrogen in the gas piston to a predetermined pressure. This pressure becomes the supply pressure for the hardware required for a pulse dosing system.

The Series III system is offered as a stand-alone package for those customers who do not want an integrated system. However, Trexel will also sell the Series III MuCell system designed for seamless integration by injection molding machine manufacturers into their existing and new small machine designs.

The MuCell Microcellular Foam technology is a complete process and equipment technology that enables the production of extremely high quality plastic parts. MuCell Technology involves the use of precisely metered quantities of atmospheric gases (nitrogen or carbon dioxide) in any of the three most common thermoplastic conversion processes (injection molding, extrusion, blow molding) to create millions of nearly invisible microcells in the end product. The creation of these microcellular structures brings a wide array of benefits including reduced weight, reduced material usage and reduced production costs.

The MuCell process is primarily employed in the injection molding process to produce lower cost precision parts with a consistently high quality and exceptional dimensional stability, where foaming has not historically been deployed.

Microcellular foaming technology was originally conceptualized and invented at the Massachusetts Institute of Technology (MIT) and in 1995 Trexel was granted an exclusive worldwide license for the further development and commercialization of the technology. Today there are hundreds of MuCell parts, both molded and extruded in commercial production today around the world and in excess of 300 machines in operation. Examples of MuCell products include electrical components, electronics connectors, internal business equipment and printer components, a variety of packaging applications and a broad array of automotive products including HVAC components. To support global adoption, Trexel has established a global network of exclusive manufacturing relationships to produce the company's proprietary precision engineering equipment. MuCell support centers are located in the U.S., Germany, Japan, Hong Kong, China, Singapore, Australia and Korea.

Trexel is the exclusive developer of the MuCell microcellular foam technology and has an extensive portfolio of patents in the U.S., Canada, Europe, Japan, Korea, and Asia. Trexel’s primary business is the supply of MuCell Systems for the production of foamed injection molded and extruded articles. It also provides world-class engineering support, training and other services, and the equipment and components integral to the MuCell process. In support of these activities, Trexel operates a foamed plastics development laboratory in its Woburn, MA facility including injection molding and extrusion equipment.

The Chen Hsong Group was established by Dr. Chen Chiang in 1958, and has grown from a small machinery workshop to one of the largest manufacturers of injection molding machines in the world. A full range of machines, with clamping force from 20 tons to 6,500 tons, is produced and sold to customers in more than 65 countries worldwide, including China, Taiwan, the United States, Canada, France, the United Kingdom, Brazil, Argentina, Mexico and most parts of Southeast Asia. The Chen Hsong Group also offers a wide range of additional products, including robotic arms, precision molds, PET preform turnkey systems, and spheroidal graphite cast iron.

Chen Hsong, with headquarters in Hong Kong, has set up a number of wholly owned subsidiaries or joint ventures in both Mainland China and in other parts of the world. In 2000, Chen Hsong relocated to a new 560,000-sqm facility in Shenzhen, China. The Chen Hsong Industrial Park, one of the world’s largest production bases, serves as the Group’s flagship manufacturing, research and technology center.

** TECHNYL** XCel are registered trademakrs of Rhodia Polamides.

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