The essence of the KP Technology is to enable simultaneous control over three core parameters which govern the overall crystallization dynamics of any polymer, namely: (i) the local pressure exerted on the polymer melt, (ii) the pressure-dependant local crystallization temperature, (iii) the degree of ordering introduced into the polymer melt.
Conventional polymer processing technologies do not focus on combining these three core parameters with the intention of triggering the effects of flow-enhanced nucleation & crystallization, but instead rely on quiescent crystallization, which is essentially determined by time and temperature.
More elaborate details on the underlying scientific narrative can be found on the Technology page of our website.
Installing melt ordering is relevant for both amorphous (e.g. PC, PS) and semi-crystalline (e.g. PET, PP, PE et al) polymers, as the ordering introduced will in itself already lead to improved performance characteristics.
Specifically for semi-crystalline polymers, the KP Technology will trigger flow-enhanced morphological structures inside the polymer melt, such as - but not limited to - oriented amorphous coils, subcritical nuclei, precursors and fine-grained flow-induced crystals.
Polymer processing technologies which will benefit from incorporation of the KP Technology are: 1-Injection Stretch Blow Molding (ISBM); 2- Direct Injection (DI); 3- Extrusion Blow Molding (EBM)
The underlying scientific basis of the KP Technology, namely flow-induced nucleation & crystallization, has been abundantly researched and described in scientific literature. We refer you to the Technology Page / References for more thorough information. Thus far, the focus has been on academic study and only limited attention has been given to any potential industrial applications.
Flow-Induced Crystallization requires the introduction of melt ordering, whether through shear or extensional-based deformations. The incumbent polymer processing industry has focused on the limitations imposed by the bulk rheology of the polymer, and has therefore never considered the application of melt ordering.
Keiryo Packaging has taken a fundamentally fresh perspective and has looked beyond these limitations, recognizing the potential offered by polymer melt ordering.
Yes, because it combines several parameters which can lead to technology disruption, specifically:
(1) the application of cutting-edge yet well-founded new scientific insights (flow-enhanced nucleation & crystallization)
(2) a fast global technology roll-out based on low capital requirements for technology adoption
(3) the opportunity to create new industry margins and/or to reallocate existing industry margins
(4) competitive insulation based on proprietary patents and/or know-how
The combination of the above parameters will enable the KP Technology to become a new technology standard in the plastic processing industry.
When designing the KP products to be integrated into existing polymer conversion equipment, Keiryo Packaging needs to consider all the geometric constraints of the existing machinery for the external configuration. For the internal configuration, the application of the KP Technology requires the integration of complex flow channels.
The resulting product would be very difficult, if not impossible, to make with conventional machining technologies. Or else it would become very costly, thereby increasing the required capital outlay for technology conversion. This would in turn negatively impact on the overall Technology adoption cycle.
The 3D metal printing industry has substantially matured as regards its technological capabilities, and is fully capable of making such complex flow geometries at high volumes and with low pricing, which is ideal for technology roll-out.
The ongoing concentration of 3D printing companies also facilitates controlled access to the KP Technology and will promote an efficient delivery cycle.