Effect of rapid heating cycle injection mold temperature on crystal structures, morphology of polypropylene and surface quality of plastic parts

Application and Optimization of the Thin Electric Heater in Micro-Injection Mold for Micropillars

The development of variotherm systems has helped to improve the quality of micro-injection molded products. Thin electric heaters have significant advantages in size, efficiency and installation convenience. However, the use of thin electric heaters has brought the problem of non-uniform temperature distribution of the insert. The good replication of the functional surfaces containing microstructures quickly and uniformly is still a challenge. In this work, the heating performance of the thin electric heater in a variotherm system is investigated by combining numerical simulations with experiments. Micro-injection molding of PP micropillars was also performed. The obtained results show that the addition of a transition layer with high thermal conductivity in the heating structure can optimize the uniformity of the temperature distribution of the insert. Furthermore, the replication heights of the micropillars can be significantly increased by the developed variotherm mold, which provides a new idea for the optimal design of a local variotherm system.

Design and Simulation Study of the Induction Heated Injection Mold with Sliders

In order to increase the quality of the products manufactured by injection molding, RTC technology can be used to achieve higher mold temperatures. As a result, the path of the injected melt can be extended, allowing the production of parts with more complex shapes and greater length. Induction heating allows heating only selected forming surfaces of the mold which increases the speed and efficiency of the process. This paper presents the concept of a detachable inductor integrated with sliders to enable the application of this technology in an injection mold with sliders, along with the theoretical model used to perform the tests. First, the effect of the magnetic concentrator shape on the process was analyzed. This was followed by a simulation study of the influence of process parameters: heating time, frequency, and electric current. An extensive analysis of the test results of the temperature distribution on the insert allowed for the selection of parameter sets that would enable obtaining the desired surface temperature without a major increase in process time. The results of simulation studies confirm the possible applications and present the range of parameters for obtaining the optimal process.

Morphology-Mechanical Performance Relationship at the Micrometrical Level within Molded Polypropylene Obtained with Non-Symmetric Mold Temperature Conditioning

The control of the structural properties of a polymeric material at the micro and nano-metrical scale is strategic to obtaining parts with high performance, durability and free from sudden failures. The characteristic skin-core morphology of injection molded samples is intimately linked to the complex shear flow, pressure and temperature evolutions experienced by the polymer chains during processing. An accurate analysis of this morphology can allow for the assessment of the quality and confidence of the process. Non-symmetric mold temperature conditions are imposed to produce complex morphologies in polypropylene parts. Morphological and micromechanical characterizations of the samples are used to quantify the effects of the processing conditions on the part performance. Asymmetric distribution of temperatures determines asymmetric distribution of both morphology and mechanical properties. The inhomogeneity degree depends on the time that one side of the cavity experiences high temperatures. The spherulites, which cover the thickest of the parts obtained with high temperatures at one cavity side, show smaller values of elastic modulus than the fibrils. When the polymer molecules experience high temperatures for long periods, the solid-diffusion and the partial melting and recrystallization phenomena determine a better structuring of the molecules with a parallel increase of the elastic modulus.

Microstructure, Tensile Property, and Surface Quality of Glass Fiber-Reinforced Polypropylene Parts Molded by Rapid Heat Cycle Molding

The microstructure of a molded product considerably influences its macroscopic properties. In this study, the influence of molding process on microstructure, tensile property, and surface quality was explored on the glass fiber-reinforced polypropylene (GFRPP) parts molded by rapid heat cycle molding (RHCM) and conversion injection molding (CIM). Tensile strength and surface gloss were chosen to measure macroscopic properties of the molded parts. The microstructure including multilayer, fiber orientation, crystallinity, and fiber-matrix bonding strength were analyzed by simulations, scanning electron microscopy, wide-angle X-ray diffraction, and dynamic mechanical analysis. The relationship between the macroscopic properties and microstructure of the RHCM samples was also discussed. The results indicate that as the mold cavity surface temperature increases, the tensile strength increases firstly and decreases thereafter. The tensile strength of RHCM parts reached the maximum at the mold heating temperature of 60°C. It is also observed that the surface gloss of the sample increases as the mold cavity surface temperature rises, and the increase of surface gloss decreases distinctly with the mold heating temperature higher than 90°C.

Effect of Rapid Mold Heating on the Structure and Performance of Injection-Molded Polypropylene

The tailoring by the process of the properties developed in the plastic objects is the more effective way to improve the sustainability of the plastic objects. The possibility to tailor to the final use the properties developed within the molded object requires further understanding of the relationship between the properties of the plastic objects and the process conduction. One of the main process parameters that allow adjusting the properties of molded objects is the mold temperature. In this work, a thin electrical heater was located below the cavity surface in order to obtain rapid and localized surface heating/cooling cycles during the injection molding process. An isotactic polypropylene was adopted for the molding tests, during which surface temperature was modulated in terms of values and heating times. The modulation of the cavity temperature was found able to control the distribution of relevant morphological characteristics, thus, properties along the sample thickness. In particular, lamellar thickness, crystallinity distribution, and orientation were analyzed by synchrotron X-ray experiments, and the morphology and elastic modulus were characterized by atomic force microscopy acquisitions carried out with a tool for the simultaneous nanomechanical characterization. The crystalline degree slightly increased with the cavity temperature, and this induced an increase in the elastic modulus when high temperatures were adopted for the cavity surface. The cavity temperature strongly influenced the orientation distribution that, on its turn, determined the highest values of the elastic modulus found in the shear layer. Furthermore, although the sample core, not experiencing a strong flow field, was not characterized by high levels of orientation, it might show high values of the elastic modulus if temperature and time during crystallization were sufficient. In particular, if the macromolecules spent adequate time at temperatures close to the crystallization temperature, they could achieve high levels of structuring and, thus, high values of elastic modulus.