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Trexel Develops TecoCell®, Chemical Foaming Agents for Unfilled PP and PE Materials

Published on 2015-09-10. Author : SpecialChem

Trexel Inc. is widely known as the company that developed and commercialized the MuCell Process for the production of microcellular foamed parts in injection molding, blow molding and extrusion. This additive system, originally developed by Polyfil, represents the next generation in chemical foaming technologies. Having only one reaction point, unlike most foaming additive systems, TecoCell does not produce corrosive byproducts or require scavenger technology. Trexel has exclusive rights to commercialize TecoCell for all injection molding and automotive blow molding applications, while Polyfil will market their EcoCell line of CFA’s for extrusion opportunities.

Trexel
Fig. 1: Trexel

TecoCell has a reaction temperature of 200C (393F), at which point the system releases CO2 to create a microcellular structure in the range of 20-80 microns. As with all foaming systems, the optimum size of the cell will depend on the process conditions and type of material used as well as the part geometry. This system is targeted at injection molding across all industries and specifically at automotive blow molding applications. Weight reductions of 30-35% for blow molding and 7-10% for injection molding parts are typical for this additive package. The blow molding applications have seen excellent property retention.

TecoCell, which is produced through a specialized and patented process, creates a homogeneous gas/cell matrix by utilizing uniform size CaCO3 particles of .08 microns.

The CaCO3 nano particles distribute themselves evenly in the material system, resulting in a strong and constant cell structure throughout the blow molded or injection molded part. The uniformity of the cell gives the user a light weight part with low warpage, faster cycles times, better stiffness and higher heat distortion properties. This even distribution and small cell size of the TecoCell additive is especially effective in unfilled PP and PE materials. These materials are commonly used for blow molded automotive ducts and injection molded thin wall packaging. See Figures 1 and 2 on page 3 for examples of PP and HDPE foamed with TecoCell.

The new automotive CAFÉ standards demanding the need for lighter weight parts in new vehicles is driving a need for blow molded ducts with the same functionality at a lower density. TecoCell can be blended into existing accumulator blow molding systems to see weight reductions of up to 35%.

Packaging applications will benefit from TecoCell product both to save material costs and to improve material flow.

“Trexel will now be able to bring it’s extensive know how and global applications support expertise to those companies for which TecoCell represents a cost effective solution for weight reduction and quality improvement in injection molding and blow molding,” commented Levi Kishbaugh, Trexel Vice President, Engineering.

About Trexel, Inc.


Trexel, Inc., headquartered in Wilmington, MA, has led the development of the MuCell® microcellular foaming injection molding technology and has pioneered many plastic processing solutions. The MuCell® technology provides unique design flexibility and cost savings opportunities by allowing plastic part design with material wall thickness optimized for functionality and not for the injection molding process. The combination of density reduction and design for functionality often results in material and weight savings of more than 20%. The numerous cost and processing advantages have led to rapid global deployment of the MuCell® process in automotive, consumer electronics, medical, packaging and consumer goods applications. Process deployment as well as equipment is supported by teams of highly qualified engineers through Trexel subsidiaries in North America, Europe, and Asia.

Trexel recently extended its product offering with the TecoCell® system. TecoCell is a unique chemical foaming technology that provides uniform microcellular structure to injection-molded parts.

Source: Trexel
 


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