AVK Innovation Award 2007: AquaCell® - Physical Foaming with Water

AquaCell^® is a new patented process for the production of physical foamed injection moulded plastic parts developed by MoellerTech GmbH, a subsidiary of the MoellerGroup GmbH & Co. KG. Using special natural fibres as a carrier the foaming agent water is introduced into the polymer. In contrast to existing physical foaming techniques AquaCell^® does not need extensive modifications of the injection moulding machine. With the aid of an external mixing machine the polymer granules, the natural fibres and the foaming agent water are intermingled to a foamable plastic blend which can be processed on an injection moulding machine.

AquaCell^® therefore combines the easy applicability of a chemical foaming process with the superior foaming rate of a physical foaming agent.

Using water as the most efficient foaming agent AquaCell^® is well-suited for the production of fibre-reinforced materials. The resulting parts have a high stability and strength due to the sandwich layer structure of the foam. Polymer consumption and weight of the parts are significantly reduced and the dimensional stability is improved. Parts with a thickness exceeding about 4 mm are difficult to produce with the existing physical foaming processes. Water has a unique combination of properties which makes it an ideal foaming agent for the production of parts with low as well as high wall thickness and a combination thereof.

In addition to these advantages, the foaming system consisting of water and natural fibres has significant economical as well as ecological benefits. Using water as foaming agent polymer use and energy consumption are reduced: with this unique advantage the AquaCell^® process is an active contribution to the conservation of our natural resources.

 

2007/11/06

 

 

 

 

 

 

 

 

 

 

"Most Innovative Use of Plastic"

 

MöllerTech GmbH receives an award for the production of Blow-Moulded Seat Backrests

 

Audi AG and Dow Automotive received an award in December 2006 for the concept of a fully structured Blow-Moulded Seat Backrest for the Audi TT Roadster. Instead of from the typical steel structures, the Seat Backrests were made here from PC-ABS, which in addition to weight reduction offers the benefits of investment and structure cost savings.

The concept for material and design originated in the Dow Automotive Center Germany, whereas MöllerTech GmbH took over the production of the parts. The finished seats were delivered by the company Lear to Audi AG.