Experimental study of injection-compression molding of film insert molded plates

Lee, Ho-Sang; Park, Jong-Rak

doi:10.1007/s12541-014-0357-2

Cited by 7 publications

(8 citation statements)

References 13 publications

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“…Future work should also focus on the combination of insert moulding and injection compression moulding to minimize the blister formation in FIM parts. Compression moulding has seen successfully used for the FIM process in several studies [29,30] and forms a strong basis for future research both for experimental and numerical activities.…”

Section: Discussionmentioning

confidence: 99%

Blister Formation in Film Insert Moulding

et al. 2020

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The formation of blister in the injection moulded parts, especially in the film insert moulded parts, is one of most significant causes of part rejection due to cosmetic requirements or functionality issues. The mechanism and physics of blister formation for molded parts are not well-understood by the state-of-the-art literature. The current paper increases the fundamental understanding of the causes for blister formation. In the experiment, a membrane strip of 5 mm in width was overmoulded with Polypropylene (PP), which formed a disc-shaped part with a diameter of 17.25 mm and a thickness of 500 µm. To investigate the influence of the processing parameters, a full factorial design of experiments (DoE) setup was conducted, including mould temperature (Tm), barrel temperature (Tb), injection speed (Vi) and packing pressure (Pp) as variables. The degree of blistering at the surface was characterized by the areal surface roughness parameters Spk and Smr1, measured with a confocal laser microscope. The measurements were taken on the 10 mm long section of the membrane surface in the centre of the moulded part across the entire width of the film. In addition, the film insert moulding (FIM)-process was simulated and the average shrinkage of the substrate material under the membrane was investigated. Eventually, a method and processing window could be defined that could produce blister-free parts.

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Section: Discussionmentioning

confidence: 99%

Blister Formation in Film Insert Moulding

et al. 2020

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“…It is thus an indispensable technology for precise and high-quality component fabrication. [11][12][13][14][15] However, the quality of ICM components is crucially dependent on the processing parameters which have both individual and interactive effects on the molded part quality. Consequently, determining the optimal processing conditions is extremely challenging.…”

Section: Introductionmentioning

confidence: 99%

Taguchi–gray relational analysis of eccentricity and tilt of multilens module mount fabricated by injection compression molding

Lin,

Lin

2024

Polymers for Advanced Techs

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This study utilizes the mold flow analysis technique of the injection compression molding (ICM) process, combined with the Taguchi–gray relational analysis (GRA), for process optimization analysis on the roundness of the lens holes and the flatness of the lens mount in a 4 × 4 planar multilens array mount. After manufacturing simulation analysis, the eccentricity and tilt information of the lens mount was further evaluated optically through spot diagram analysis upon inserting the same glass lenses. The results showed a positive correlation trend between roundness and flatness in structural deformation analysis, indicating that improving the overall flatness of the lens mount can enhance the roundness of the lens holes. In optical analysis, better improvements in the lens tilt angle were achieved through GRA. In conclusion, aiming to simultaneously improve the roundness of the lens holes and the overall flatness of the lens mount, the Taguchi–GRA method can achieve the optimization objectives. In terms of optical performance, by optimizing for roundness, it is possible not only to reduce the diameter of the light spot but also to simultaneously reduce the offset displacement of the light spot center on the screen. The method proposed in this paper can serve as an analytical model for the design and fabrication of plastic multilens mount.

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“…Finally, the mold is opened and the finished part is ejected and allowed to cool naturally to room temperature (Figure 1D). [1][2][3][4] The ICM process provides a quick and convenient approach for the mass production of plastic components with both simple and complex geometries. However, residual stress is easily accumulated within the molded component during the compression and packing stages, and this often leads to the warpage of the component as it undergoes cooling following ejection from the mold.…”

Section: Introductionmentioning

confidence: 99%

“…Finally, the mold is opened and the finished part is ejected and allowed to cool naturally to room temperature (Figure 1D). 1–4 …”

Section: Introductionmentioning

confidence: 99%

Injection‐compression molding process on optical quality optimization of plastic lens array

Lin,

Lin

2023

Polymers for Advanced Techs

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Plastic lens arrays (PLAs) have the advantages of a light weight and a compact size. However, their optical performance is often degraded by warpage, caused by the accumulation of residual stress during the injection molding process. Accordingly, the present study employs mold flow analysis simulations and a Taguchi‐Gray relational analysis (GRA) framework to optimize the processing parameters of the injection compression molding (ICM) process. The analyses focus specifically on the effects of the mold temperature, melt temperature, injection velocity, packing pressure, packing time, and compression gap on the optical path difference (OPD) and lens center displacement (LCD) of the fabricated lens array. The results confirm that the optimized processing parameters significantly improve the OPD, LCD, birefringence, and imaging properties of the PLA compared to those of a PLA fabricated using standard molding conditions.

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Experimental study of injection-compression molding of film insert molded plates

Cited by 7 publications

References 13 publications

Blister Formation in Film Insert Moulding

Blister Formation in Film Insert Moulding

Taguchi–gray relational analysis of eccentricity and tilt of multilens module mount fabricated by injection compression molding

Injection‐compression molding process on optical quality optimization of plastic lens array

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