Thermal effects on the behaviour of PET films used in the in-mould-decoration process involved in plastics injection moulding

Wong, Ast; Liang, Kangli

doi:10.1016/s0924-0136(96)02674-x

Cited by 18 publications

(8 citation statements)

References 2 publications

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“…[4] The most common process technology is categorized into four types: (i) double (dissimilar metal materials) injection molding (overmolding), (ii) in-mold decoration injection molding (in-mold decoration), (iii) laser cutting (laser structuring), and (iv) hot pressing (hot embossing). [7,8] Each phase of the IMD process influences the quality of the finished products. IMD process equipment is inexpensive and is comprised of four main phases of the process: (i) film printing, (ii) 3D film molding, (iii) film cutting, and (iv) film insert injection molding.…”

Section: Introductionmentioning

confidence: 99%

“…Studies in 2011 include successful cases with most of the cases associated with the laser and overmolding process; however, laser process equipment is quite expensive. IMD process equipment is inexpensive and is comprised of four main phases of the process: (i) film printing, (ii) 3D film molding, (iii) film cutting, and (iv) film insert injection molding . Each phase of the IMD process influences the quality of the finished products.…”

Section: Introductionmentioning

confidence: 99%

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Design of the printing pattern on film for three‐dimensional molded interconnect devices

2017

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This article discusses the application of an in-mold decoration (IMD) technology for the development of three-dimensional molded interconnect devices (3D-MID). The 3D-MID process uses the film printing technology to print the circuit pattern on a plastic film, and then deform it to the shape of the component by thermoforming.Then, the plastic film is placed inside the mold cavity for injection molding, and is attached to the surface of the component after molding. Experiments were performed for the 3D-MID process using a semisphere shape. A simple geometric model was also proposed to correlate the printed film patterns before and after the thermoforming. The geometric model will be used to design the required printing pattern on a 2D film for a given 3D pattern on a component. K E Y W O R D Sinjection molding, in-mold decoration, thermoforming, three-dimensional molded interconnect devices

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Design of the printing pattern on film for three‐dimensional molded interconnect devices

2017

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“…Once the object is ejected from the mold, the graphics on the film cannot be removed, as the cooled object and film form asingle unit (Fig. 1C) (Wong et al, 1997;Leong et al, 2007;Liu et al, 2012;Puentes et al, 2009). IMD can achieve different colors, effects, and textures when the part comes out of the mold.…”

Section: Introductionmentioning

confidence: 99%

Factors Influencing the Warpage in In-Mold Decoration Injection Molded Composites

Lee

Chen

Huang

et al. 2013

International Polymer Processing

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This report studied, both experimentally and numerically, the factors affecting the warpage in in-mold decoration (IMD) injection molded parts. All experiments were conducted on an 80-ton injection-molding machine. The materials used in the experiments included poly(ethylene terephthalate) (PET) films and 30 %g lass fiber-filled PET resins. U-shaped plate parts with three different angles (908 ,1 358 ,a nd 1508)a tt he corners were molded. The influence of various processing parameters on part warpage was investigated using an experimental matrix, with its design based on the experimental-parameterdesign method developed by Taguchi. The experimental results suggested that all molded parts warped toward the side of the decoration film. For the parameters selected in the experiments, the corner angle and the melt injection pressure were found to be the principal factors affecting the warpage of IMD injection molded parts. The 908 angled parts exhibited the greatest amount of warpage, while the 1508 angled parts showed the least amount of warpage. Additionally, acommercially available code (Moldex 3-D) was used to simulate the temperature distribution during the filling process and the molded part warpage. Calculated warpage satisfactorily matched with the experimental data. It has been shown that the warpage of IMD injection molded parts is mainly caused by the imbalanced temperature distributiond uring cooling, due to the part geometry and the decoration films.

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“…In-mould Decoration (IMD) is a process to produce the aesthetic moulded components whereby a film with decorative elements is being moulded together with the plastic to create decorative patterns and reduce the secondary process of graphics and screen printing (Wong A.C-Y 1997). The IMD fabrication process follows four main steps, i.e., screen printing, thermal forming, trimming and moulded to be some parts by injection moulding as presents in Figure 1 and Figure 2.…”

Section: In-mould Decoration Componentsmentioning

confidence: 99%

“…The graphic design on demand could quickly alter the appearance and texture on the identical product shape (Hsieh and Chang 2013). For these reason, the in-mould decoration (IMD) injection moulding is recently-evolved process (Wong A.C-Y 1997) which combines several machining techniques and mould fabrication technology. During the IMD process, a pre-painted film is placed in the mould cavity prior to injection.…”

Section: In-mould Decoration Manufacturingmentioning

confidence: 99%

Defect Reduction In Manufacturing Process Of In-Mold Decoration Of Injection Molded Components

Supapan

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The purpose of this research is to reduce the defect rate from manufacturing process of in-mould decoration (IMD), a process combining PET film with decorative patterns are moulded together with ABS resins, which has been developed to reduce the secondary process of decorative screen printing. Recently, the case study company has produced components with a high defect rate average 11.43% in Feb-Jun 2018, which increased sharply to 22.3% in June 2018. The major causes of the defect resulting from PET film peeled off and difficult to assembly. In order to reduce the defect rate, the five steps of the DMAIC Six Sigma methodology are implemented. The detail of the IMD manufacturing process was studied to identify appropriate measurement methods and factors affecting PET film peeled off by using the cause and effect diagram and its scoring matrix. Then the prioritized factors were analyzed and selected from FMEA to conduct the design of experiment (DOE) to find significant factors and optimal parameter settings for improvement and control process to prevent reoccurrence. After improvement of PET film peeled off by setting appropriate parameter as well as implementing control plans and Standard Operation Procedure (SOP) to eliminate other defects from in-mould decoration process, the result shows that the defect rate of in-mould decoration process decreased from11.43% average in Feb-June 2018 to1.25% after improvement in July-Oct 2018. It is found that IMD peeled off defect is reduce 86.6% and warpage defect is reduce 97.8% of defect before improvement.

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Thermal effects on the behaviour of PET films used in the in-mould-decoration process involved in plastics injection moulding

Cited by 18 publications

References 2 publications

Design of the printing pattern on film for three‐dimensional molded interconnect devices

Design of the printing pattern on film for three‐dimensional molded interconnect devices

Factors Influencing the Warpage in In-Mold Decoration Injection Molded Composites

Defect Reduction In Manufacturing Process Of In-Mold Decoration Of Injection Molded Components

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