Dynamic mold surface temperature control using induction heating and its effects on the surface appearance of weld line

Chen, Shia‐Chung; Jong, Wen-Ren; Chang, Jyh-Cheng

doi:10.1002/app.24070

Cited by 131 publications

(82 citation statements)

References 7 publications

(5 reference statements)

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“…Chen et al proposed electromagnetic induction heating [10,11], combined with mold temperature cooling. [12].…”

Section: Introductionmentioning

confidence: 99%

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Effect of fast mold surface temperature evolution on iPP part morphology gradients

Liparoti¹,

Sorrentino²,

Guzman³

et al. 2016

AIP Conference Proceedings

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Influence of mold surface temperature on polymer part warpage in rapid heat cycle molding AIP Conference Proceedings 1593, 189 (2014) The control of mold surface temperature is an important factor that affects the sample surface morphology as well as the structural gradients (orientation crystal size, and type) as well as cooling stresses. The frozen layer thickness formed during the filling stage also has a very significant effect on the flow resistance and thus on the resulting pressure drop and flow length in thin wall parts. The possibility to have a hot mold during filling and a quick cooling soon afterward is a significant process enhancement particularly for specialized applications such as micro injection molding and for the reproduction of micro structured surfaces. Up to now, several methods (electromagnetic, infrared, hot vapor fleshing etc,) were tried to achieve fast temperature evolution of the mold. Unfortunately, all these methods require a complex balance between thermal and mechanical problems, equipment cost, energy consumption, safety, molding cycle time and part quality achievable.In this work, a thin electrical resistance was designed and used to generate a fast and confined temperature variation on mold surface (by joule effect). Since the whole temperature evolution can take place in a few seconds, one can couple the advantages of a high surface temperature during filling with the advantages of a low mold temperature, fast cooling and low heating dissipation. Some experiments were performed with a commercial iPP resin. The effects of the surface temperature and of the heating time (under constant electric power) on surface finishing and on the final morphology (thickness and structure of the different layers) are explored and discussed.

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“…Chen et al proposed electromagnetic induction heating [10,11], combined with mold temperature cooling. [12].…”

Section: Introductionmentioning

confidence: 99%

“…[12]. Chang et coworkers [10] and Yu and coworkers [11] developed systems based on infrared heating. Yao et al proposed proximity heating [13] for the local heating of mold surface.…”

Section: Introductionmentioning

confidence: 99%

Effect of fast mold surface temperature evolution on iPP part morphology gradients

Liparoti¹,

Sorrentino²,

Guzman³

et al. 2016

AIP Conference Proceedings

View full text Add to dashboard Cite

show abstract

“…Generally, the mold temperature is controlled by adjusting the rate and the temperature of the coolant that moves inside the mold channels. In literatures [1][2][3] is well documented how a high mold temperature has a great positive effect on the surface appearance, strength, size, and shape accuracy of the molded part, moreover, it also decreases the required injection pressure and clamping force of the molding machine [4]. However, the corresponding long cooling time, resulting from the high mold temperature, decreases the productivity and increases the costs.…”

Section: Introductionmentioning

confidence: 99%

“…Different techniques have been proposed to reach this objective, such as induction coils [2], radiation source [1] or proximity heating [5] for the local heating of mold surface. These solutions require additional design and tool cost.…”

Section: Introductionmentioning

confidence: 99%

Rapid control of mold temperature during injection molding process

Liparoti

Hunag

Sorrentino

et al. 2015

AIP Conference Proceedings

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Effect of fast mold surface temperature evolution on iPP part morphology gradients AIP Conference Proceedings 1713, 170001 (2016) Abstract. The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during the entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.

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“…For an effective thermal management system, this investigation provides a strategy to identify the thermal dynamic model for designing a controller. [15][16][17] …”

Section: Introductionmentioning

confidence: 99%

Optimized Digital Proportional Integral Derivative Controller for Heating and Cooling Injection Molding System

Jeong¹,

Kim²,

Lee³

2015

Journal of Electrical Engineering and Technology

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-Proportional integral derivative (PID) control is one of the conventional control strategies.Industrial PID control has many options, tools, and parameters for dealing with the wide spectrum of difficulties and opportunities in manufacturing plants. It has a simple control structure that is easy to understand and relatively easy to tune. Injection mold is warming up to the idea of cycling the tool surface temperature during the molding cycle rather than keeping it constant. This "heating and cooling" process has rapidly gained popularity abroad. However, it has discovered that raising the mold wall temperature above the resin's glass-transition or crystalline melting temperature during the filling stage is followed by rapid cooling and improved product performance in applications from automotive to packaging to optics. In previous studies, optimization methods were mainly selected on the basis of the subjective experience. Appropriate techniques are necessary to optimize the cooling channels for the injection mold. In this study, a digital signal processor (DSP)-based PID control system is applied to injection molding machines. The main aim of this study is to optimize the control of the proposed structure, including a digital PID control method with a DSP chip in the injection molding machine.

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Dynamic mold surface temperature control using induction heating and its effects on the surface appearance of weld line

Cited by 131 publications

References 7 publications

Effect of fast mold surface temperature evolution on iPP part morphology gradients

Effect of fast mold surface temperature evolution on iPP part morphology gradients

Rapid control of mold temperature during injection molding process

Optimized Digital Proportional Integral Derivative Controller for Heating and Cooling Injection Molding System

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