In-line rheology model for real-time polymer degradation prediction in injection molding

Overview

The proposed solution is an innovative model-based approach designed to predict polymer degradation in real-time during the injection molding process. By utilizing in-line rheology data obtained via conventional piezoelectric pressure sensors and novel ultrasound-based sensors, this technology enables early detection of degradation, thereby improving part quality and reducing waste. The model integrates seamlessly with existing mold and injection systems without the need for custom hardware modifications, providing a fast, non-destructive monitoring solution.

Technical specifications

• Sensors: Utilizes piezoelectric pressure sensors and ultrasound-based sensors for real-time data collection.
• Data Collection: Monitors machine signals such as nozzle pressure, screw position, and screw pressure.
• Processing Parameters: Capable of handling varied injection speeds, melt temperatures, and part wall thicknesses.
• Model Development: Predictive model incorporates physics-based and data-driven approaches, correlating sensor data with molecular weight degradation.
• Integration: Designed to fit within standard tooling and process windows for ease of implementation.

Technology readiness level

Currently at Technology Readiness Level 3 (TRL 3), this solution has been validated in laboratory settings through controlled molding experiments. The next steps include further validation under varied processing conditions and preparation for commercial deployment.