Specialized Injection Molding Techniques

Specialized Injection Molding Techniques
Edited by
Hans-Peter Heim
Universität Kassel, Institut für Werkstofftechnik,
Kunststofftechnik, Kassel, Germany
Table of Contents
Preface
Reference

1. Multicomponent Technologies
   Abstract
   1.1 Introduction
   1.2 Motivation
   1.3 Basic Bonding Mechanism
   1.4 Influences of Material and Process Control on the Basic Bonding Mechanism
   1.5 Machines and Processes
   References
2. Foam Injection Molding
   Abstract
   2.1 Why Foam Injection Molding?
   2.2 Foaming Mechanism
   2.3 Process Route
   2.4 Variants of Foaming Techniques
   References
3. Gas- and Fluid-Injection Technique
   Abstract
   3.1 Introduction
   3.2 Description of the GIT Procedure
   3.3 Typical Applications and Tasks
   3.4 Mechanisms of Gas Penetration
   3.5 Influencing the Form and Position of the Gas Bubble
   3.6 Influencing the Surface Quality
   3.7 Influence of Material Properties
   3.8 GIT Tools and Machine Technology
   3.9 Design of GIT Components and Tools
   3.10 Variants of Fluid Injection Technology
   References
4. Injection Molding of Multimaterial Systems
   Abstract
   4.1 Introduction
   4.2 Bonding Mechanisms in Plastic–Metal Systems
   4.3 The Influence of the Material, the Geometry, and the Process Parameter on the Component Properties
   4.4 Processing Variants
   4.5 Production of Injection Molded Organic Sheet Parts
   References
5. Injection Molding of Bio-Based Plastics, Polymers, and Composites
   Abstract
   5.1 Introduction
   5.2 Materials
   5.3 Specific Injection Molding Behavior
   5.4 Process Variants
   References
   x
   Note: Page numbers followed by “f ” and “t” refer to figures and tables, respectively.
   A
   Acetal copolymers, 190
   Adhesion, 3
   6, 24, 166
   171, 166f
   mechanical, 169
   171
   specific, 166
   169
   types, 195
   196
   Adsorption theory, 167
   “Airing”. See Precision mold opening
   (PMO)
   Amylopectin, 223
   Amylose, 223
   Anisotropy, 177
   178, 229
   AquaCells, 231
   B
   Back-pressure-method, 161
   Basic bonding mechanism, 3
   9
   adhesion, 4
   6
   diffusion, 6
   9
   influences of material and process
   control on, 10
   26
   connection design/interface
   geometry, 23
   contact time, 20
   crystallinity, 13
   injection and holding pressure,
   25
   injection speed, 25
   26
   interface compatibility, 11
   16
   interface stresses, 21
   26
   interface temperature, 16
   20
   intermediate cooling time, 20
   mass temperature/injection
   sequence, 17
   20
   mold design, 24
   mold temperature, 20
   molecular orientations, 14
   molecular weight, 13
   polarity, 14
   shrinkage, 21
   22
   surface and interface tension,
   11
   12
   surface pretreatment,
   16
   surface roughness, 23
   24
   thermal expansion behavior, 25
   thermodynamic compatibility/
   miscibility, 15
   16
   Bi-injection, 29
   30
   Bio-based plastics
   injection molding of, 211
   materials, 212
   225
   Biocomposites, 212, 219
   220,
   224
   226
   Bioplastics, 211
   212, 214
   219,
   225
   biopolyamides with a vegetable oil
   basis, 217
   218
   linkage between biopolymer and,
   212f
   polylactic acid (PLA), 219
   starch blends, 215
   216
   thermoplastic starch (TPS),
   214
   215
   Biopolyamides with a vegetable oil
   basis, 217
   218
   Biopolymers, 211
   212, 214
   Biot number, 151
   152
   Blowing agents, 56, 62, 80
   82
   chemical blowing agent, 64
   65,
   80
   81
   concentration, 82
   83
   239Blowing agents (Continued)
   physical blowing agents, 62
   64,
   81
   82, 96
   supercritical points of, 63
   64
   Bonding mechanism, 10
   26
   connection design/interface
   geometry, 23
   contact time, 20
   crystallinity, 13
   injection and holding pressure, 25
   injection speed, 25
   26
   interface compatibility, 11
   16
   interface stresses, 21
   26
   interface temperature, 16
   20
   intermediate cooling time, 20
   mass temperature/injection
   sequence, 17
   20
   mold design, 24
   mold temperature, 20
   molecular orientations, 14
   molecular weight, 13
   polarity, 14
   shrinkage, 21
   22
   surface and interface tension,
   11
   12
   surface pretreatment, 16
   surface roughness, 23
   24
   thermal expansion behavior,
   25
   thermodynamic compatibility/
   miscibility, 15
   16
   “Breathing tool”. See Precision mold
   opening (PMO)
   C
   Cadmoulds, 109
   Carbon dioxide, 81
   82
   CellMoulds, 96
   97
   Cellulosic fibers, 219
   222
   Chemical blowing agents, 64
   65,
   80
   81
   foaming using, 75
   77
   Chemisorption, 5, 166
   Coalescence, 59
   Cohesion, 4
   Composites, injection molding of,
   211
   Compressibility of the fluid,
   influence of, 153
   154
   Connection design/interface
   geometry, 23
   Constructive connection design,
   192
   193, 192f
   Contact time, 20, 21f
   “Core back expansion”. See Precision
   mold opening (PMO)
   Core back technique, 37
   38, 38f
   Core-pull method, 107
   108, 150
   Crystallinity, 13
   Cube technology, 45
   46, 46f
   double cube technology, 47
   48
   D
   Decompression, tools with, 88
   90
   precision mold opening (PMO),
   88
   90
   pull-and-foam method, 90
   Demolding shrinkage, 21
   Differential scanning calorimetry
   (DSC), 215
   Diffusion, 4, 6
   9, 25, 57
   58
   Einstein equation, 8
   9
   reptation model, 9
   Diffusion theory, 6, 167
   Double cube technology, 47
   48
   Draping, 199
   Draping simulation, 205
   206
   DSC. See Differential scanning
   calorimetry (DSC)
   Dynamic mixing elements, for
   injection molding, 76f
   Dynamic pressure, 86
   87
   E
   Einstein equation, 8
   9
   Electrostatic theory, 5, 167
   Elongational viscosity, 135
   136
   Endothermic blowing agents, 64
   65
   240 INDEXErgocell, 96
   97, 98f
   EUROMAP interface, 137
   Exothermic blowing agents, 64
   65,
   80
   81
   F
   Fault-tolerant positioning elements, 193
   FEMs. See Finite element methods
   (FEMs)
   Fiber composite technology, 194
   Fiber-reinforced plastics, 175, 192,
   232
   234
   glass, 226
   natural, 219
   220, 226
   Filling/reinforcement materials,
   influences of, 136
   FIM. See Foam injection molding
   (FIM)
   Finger effect, 33, 126
   127, 127f, 128f
   Finite element methods (FEMs), 109,
   170
   Flexural modulus, 70, 91f
   Fluid injection technology, 107,
   147
   161
   GITBlow (GIT combined with
   blow molding), 155
   159
   multilayered hollow parts
   manufactured using GIT and
   WIT, 159
   160
   overflow cavity method, 147
   150
   push-back and core-pull methods,
   150
   surface optimization, measures for,
   161
   water injection technology,
   150
   154
   Foam injection molding (FIM),
   53
   57, 231
   232
   decompression, tools with, 88
   90
   precision mold opening (PMO),
   88
   90
   pull-and-foam method, 90
   foaming mechanism, 57
   73
   cell growth, 58
   60
   chemical blowing agents,
   64
   65
   mechanical and optical
   properties, 67
   73
   mechanical properties, 67
   72
   morphology of foams, 65
   67
   nucleation, 58
   optical properties, 72
   73
   physical blowing agents, 62
   64
   solubility and diffusion, 57
   58
   stabilizing effects, 61
   62
   gas counter pressure (GCP)
   method, 90
   93
   general idea, 53
   55
   physical foaming techniques,
   96
   100
   CellMoulds, 96
   97
   Ergocell, 97
   MuCells, 96
   Optifoams, 98
   ProFoam, 99
   SmartFoams, 99
   100
   process route, 73
   87
   blowing agent concentration,
   82
   83
   chemical blowing agent, 80
   81
   chemical blowing agents,
   foaming using, 75
   77
   dynamic pressure, 86
   87
   injection speed, 86
   mass temperature, 83
   84
   mold temperature, 85
   86
   physical blowing agents, 81
   82
   physical blowing agents,
   foaming using, 77
   standard tool technique, 78
   79
   static mixing elements for
   distributing gas in the melt,
   77
   78
   sandwich technique, 94
   95
   typical applications, 56
   57
   for use in nonvisible areas, 56f
   variothermic mold temperature,
   93
   94
   INDEX 241Form bound shrinkage, 22, 22f
   Form-fitting connection options,
   172
   Free shrinkage, 22, 22f
   G
   Gas counter pressure (GCP)
   technique, 55, 90
   93, 161
   Gas injection molding, 112
   Gas injection technology (GIT),
   107
   components and tools, design of,
   139
   147
   gas-guiding geometries,
   designing, 145
   147, 145t
   melt and gas injection points,
   determination of, 139
   144
   fluid injection technology, variants
   of, 147
   161
   GITBlow, 155
   159
   multilayered hollow parts
   manufactured using GIT and
   WIT, 159
   160
   overflow cavity method,
   147
   150
   push-back and core-pull
   methods, 150
   surface optimization, measures
   for, 161
   water injection technology,
   150
   154
   form and position of gas bubble,
   influencing, 125
   128
   geometric groups, 111
   112, 113t
   machine setup for, 137f
   material properties, influence of,
   130
   136
   Carreau parameter, 131
   133,
   134f
   elongational viscosity, 135
   136
   filling/reinforcement materials,
   influences of, 136
   shear viscosity, 133
   structural viscosity, 133
   135
   mechanisms of gas penetration,
   115
   124, 116t
   cooling phase/formation of the
   quality features in the
   component, 121
   124
   gas injection/remaining filling,
   117
   121
   injection/partial filling, 110f,
   115
   116, 116f, 117f
   procedure, description of,
   110
   112
   shrinkage, 128
   130
   surface quality, influencing,
   128
   130
   tools and machine technology,
   136
   139
   gas injector, 137
   139
   gas source
   pressure
   generation
   gas control, 137
   typical applications and tasks,
   112
   114, 114t
   Gas-holding pressure, 121
   GCP technique. See Gas counter
   pressure (GCP) technique
   GIT. See Gas injection technology
   (GIT)
   GITBlow (GIT combined with blow
   molding), 155
   159
   one-step method, 156
   157
   two-step method, 155
   Glass fiber-reinforced plastics,
   226
   Glass mat-reinforced thermoplasts
   (GMTs), 194, 199, 203, 205
   GMTs. See Glass mat-reinforced
   thermoplasts (GMTs)
   H
   Heat capacity/storage capacity,
   influence of, 150
   152
   Heat transition coefficient and heat
   conductivity, influence of,
   152
   Heterogeneous nucleation, 58
   242 INDEXHolding pressure, 25, 88, 185
   Hollow space, 107, 111, 115, 123,
   130, 147, 154
   Homogeneous nucleation, 58
   I
   IMC. See Injection-molding
   compounder (IMC)
   Infrared radiators, 203
   204
   Injection and holding pressure, 25
   Injection sequence, 36
   37
   sequential process control, 37
   simultaneous process control, 36
   Injection speed, 25
   26, 86, 185
   Injection-molding compounder
   (IMC), 232
   234
   Insert molding technology, 186
   188,
   186f, 187f
   plastic
   metal connection in, 187f
   Insert technique, 40f
   Institute of Plastics Processing, 98
   99
   Interface, structure of, 168f
   Interface compatibility, 11
   16
   Interface stresses, 21
   26
   Interface temperature, 16
   20
   Interface tension, 12
   Intermediate cooling time, 20
   Internal stresses, 80, 129, 175,
   180
   183
   bonding at, 196
   197
   K
   Key technology, 1
   L
   Linear thermal expansion coefficient,
   179
   Load-bearing plastic
   metal
   structures, 191
   193
   Localized shrinkage compensation,
   160
   161
   M
   Machines and processes, 26
   48
   material combination, 27
   29
   point of material joining, 29
   36
   bi-injection, 29
   30
   injection sequence, 36
   37
   marbling technique, 34
   36
   sandwich technique, 30
   34
   tool technologies, 37
   48
   horizontal turning technologies,
   45
   48
   index plate, 43
   44
   linear systems, 44
   45
   rotary disks, 41
   43
   slider technology, 37
   39
   transfer process, 39
   41
   Marbling technique, 34
   36
   Mass temperature, 17
   20, 83
   84
   Material combination, 27
   29
   Material joining, 29
   36
   bi-injection, 29
   30
   injection sequence, 36
   37
   sequential process control,
   37
   simultaneous process control,
   36
   marbling technique, 34
   36
   sandwich technique, 30
   34
   basic method, 33
   general information, 32
   33
   monosandwich method, 31f, 34
   traditional technique, 31f
   Mechanical adhesion, 5
   6,
   169
   171
   Melt and gas injection points,
   determination of, 139
   144,
   141t
   Melt temperature, 17, 85, 183
   184
   Metal insert, 176, 193
   temperature of, 184
   Metals, surface pretreatments for,
   168, 169t
   Microcellular foams, 55
   Mold design, 24
   Mold temperature, 20, 85
   86,
   184
   185
   variothermic, 93
   94
   INDEX 243Moldexs, 109
   Moldflows, 109
   Molecular orientations, 14, 25
   26,
   178, 185
   Molecular weight, 13
   Monosandwich technique, 31f, 34
   Morphology of foams, 65
   67
   Motivation, 2
   3
   MuCells, 82
   83, 96, 97f, 231
   Multicomponent technologies, 1
   Multilayered hollow parts,
   manufacturing
   using GIT and WIT, 159
   160
   Multimaterial systems, injection of,
   165
   construction, 174
   177
   component design, 175
   177
   selection of materials, 174
   175
   injection-molded organic sheet
   parts, production of, 194
   207
   process technology, 197
   207
   thermoplastic composites,
   bonding mechanisms of,
   194
   197
   material effects, 177
   183
   anisotropy, 177
   178
   internal stresses, 180
   183
   linear thermal expansion
   coefficient, 179
   plastic
   metal systems, bonding
   mechanisms in, 166
   172
   adhesion, 166
   171
   form-fitting connections, 172
   processing variants, 186
   193
   insert technology, 187
   188
   load-bearing plastic
   metal
   structures, 191
   193
   outsert technology, 188
   191
   process parameters, 183
   185
   holding pressure, 185
   injection speed, 185
   melt temperature, 183
   184
   mold temperature, 184
   185
   temperature of the insert, 184
   N
   Natural fiber, 220
   221
   classification of, 219f
   plant-based, 221
   -reinforced plastics, 219
   220, 224,
   226, 231
   “Negative injection compression
   molding”. See Precision mold
   opening (PMO)
   Nitrogen gas, 81
   82
   Nucleation, 58
   O
   Optifoams, 96, 98, 99f
   Organic sheet parts, injectionmolded, 194
   207
   process technology, 197
   207
   process sequences, 200
   207
   process structure, 198
   200
   thermoplastic composites, bonding
   mechanisms of, 194
   197
   bonding at internal stresses,
   196
   197
   types of adhesion, 195
   196
   Organic sheets, 165, 194
   preparation of, 202
   203
   Outsert molding technology,
   188
   191
   plastic
   metal connection
   in, 190f
   Overflow cavity method, 109
   111,
   147
   150
   P
   PAs. See Polyamides (PAs)
   PBT. See Polybutylene terephthalate
   (PBT)
   PC. See Polycarbonate (PC)
   PE. See Polyethylene (PE)
   PET. See Polyethylene terephthalate
   (PET)
   Physical blowing agents, 62
   64,
   81
   82
   foaming using, 77
   244 INDEXPhysical foaming techniques,
   96
   100
   CellMoulds, 96
   97
   Ergocell, 97
   MuCells, 96
   Optifoams, 98
   ProFoam, 99
   SmartFoams, 99
   100
   Plant-based natural fibers, 221
   Plastic composites, injection molding
   of
   basic bonding mechanism, 3
   9
   adhesion, 4
   6
   diffusion, 6
   9
   basic bonding mechanism, material
   and process control on,
   10
   26
   connection design/interface
   geometry, 23
   contact time, 20
   crystallinity, 13
   injection and holding pressure,
   25
   injection speed, 25
   26
   interface compatibility, 11
   16
   interface stresses, 21
   26
   interface temperature, 16
   20
   intermediate cooling time, 20
   mass temperature/injection
   sequence, 17
   20
   mold design, 24
   mold temperature, 20
   molecular orientations, 14
   molecular weight, 13
   polarity, 14
   shrinkage, 21
   22
   surface and interface tension,
   11
   12
   surface pretreatment, 16
   surface roughness, 23
   24
   thermal expansion behavior,
   25
   thermodynamic compatibility/
   miscibility, 15
   16
   machines and processes, 26
   48
   material combination, 27
   29
   point of material joining, 29
   36
   tool technologies, 37
   48
   motivation, 2
   3
   multicomponent technologies, 1
   Plastic
   metal composite, 165,
   173
   174, 176, 177f, 179, 183
   Plastic
   metal hybrid injection
   molding, 186f, 191, 193
   Plastic
   metal systems, bonding
   mechanisms in, 166
   172
   adhesion, 166
   171
   mechanical adhesion, 169
   171
   specific adhesion, 166
   169
   form-fitting connections, 172
   Plastic-plastic composites, injectionmolded, 2
   Plastics
   fiber reinforcement, 192
   shrinking behavior of, 190, 191f
   structural viscosity of, 133
   135
   PMO. See Precision mold opening
   (PMO)
   Polarity, 14
   Polarization theory, 5, 167
   Polyamides (PAs), 190, 217
   with vegetable oil basis, 217
   218
   Polybutylene terephthalate (PBT),
   217
   Polycarbonate (PC), 69
   70, 83
   Polyethylene (PE), 226
   227
   Polyethylene terephthalate (PET), 217
   Polylactic acid, 219
   Polymer-gas mixture, 57, 73
   74, 79,
   98
   Polymers, injection molding of, 211
   Polypropylene (PP), 81, 226
   227
   Polysaccharides, 213
   214
   Polytrimethylene terephthalate (PTT),
   217
   Polyurethane (PUR), 217
   Pore density, 68
   69, 82
   83
   Postshrinkage, 21
   INDEX 245PP. See Polypropylene (PP)
   Precision mold opening (PMO), 88
   90
   Preheating, 203
   206
   “Process Sequences”, 195
   196,
   200
   207
   Processing shrinkage, 21
   Processing variants, 186
   193
   insert technology, 187
   188
   load-bearing plastic
   metal
   structures, 191
   193
   outsert technology, 188
   191
   ProFoam, 99
   PTT. See Polytrimethylene
   terephthalate (PTT)
   Pull-and-foam method, 90, 91f
   Pulling injectors, 139
   PUR. See Polyurethane (PUR)
   Push-back method, 121, 150
   Push-button effect, 170
   PvT-behavior, 180
   R
   Reflection electron microscopy
   (REM), 229
   230
   Relocating technique, 40f
   REM. See Reflection electron
   microscopy (REM)
   Remaining wall thickness (RWT),
   115, 123, 130
   131
   definition of, 131f
   measurement, 130
   rheological influences on, 132f
   Rotary central block, 45
   46
   Rotary disk and cube mold, 188, 189f
   Roughness
   geometries of, 170f
   surface roughness, 23
   24, 92, 92f,
   95
   RWT. See Remaining wall thickness
   (RWT)
   S
   Sandwich technique, 30
   34, 94
   95
   basic method, 33
   general information, 32
   33
   monosandwich method, 31f, 34
   traditional technique, 31f
   SB. See Styrene butadiene (SB)
   Semicrystalline plastics, 7, 13,
   15
   17, 175
   Shear viscosity, 133
   Shrinkage, 21
   22, 40
   41, 61
   62
   demolding, 21
   form bound, 22, 22f
   free, 22, 22f
   localized shrinkage compensation,
   160
   161
   postshrinkage, 21
   processing, 21
   Side cavity method. See Overflow
   cavity method
   SIGMASOFTs, 109
   Single-material systems, 194,
   196
   197
   Single-phase polymer-gas mixture,
   57, 73
   74, 86
   87
   SmartFoams method, 99
   100
   Solidworkss, 109
   Solubility, 57
   58
   Specific injection-molding behavior,
   225
   230
   injection molding, characteristics
   in, 225
   226
   biocomposites,
   226
   bioplastics, 225
   process-induced material
   properties, 226
   230
   process variants, 231
   234
   foam injection molding,
   231
   232
   injection-molding compounder,
   232
   234
   Stabilizing effects, 61
   62
   Stack turning technologies, 45
   48
   Starch as filling material, 222
   223,
   223t
   Starch blends, 215
   216
   246 INDEXStatic mixing elements for
   distributing gas in the melt,
   77
   78
   Stationary injectors, 139
   Stiffness of the foam core, 70
   71
   Structural viscosity, 133
   135
   Styrene butadiene (SB), 151
   152
   Supercritical fluid, 63f
   Supersaturation, 82
   83
   Surface and interface tension, 11
   12
   Surface optimization, measures for,
   161
   Surface pretreatment, 16
   for metals, 169t
   Surface roughness, 23
   24, 92, 92f
   Surface tension, 11
   12
   T
   Temperature-dependent reptation
   time, 9
   TGA. See Thermogravimetric
   analysis (TGA)
   Thermal expansion behavior, 25
   Thermodynamic compatibility/
   miscibility, 15
   16
   Thermodynamic theory, 5
   6
   Thermogravimetric analysis (TGA),
   221
   222
   Thermoplastic composites, bonding
   mechanisms of, 194
   197
   Thermoplastic foam injection
   molding. See Foam injection
   molding (FIM)
   Thermoplastic starch (TPS),
   214
   215
   Tool technologies, 37
   48
   classification of, 38f
   horizontal turning technologies,
   45
   48
   index plate, 43
   44
   linear systems, 44
   45
   rotary disks, 41
   43
   slider technology, 37
   39
   transfer process, 39
   41
   TPS. See Thermoplastic starch (TPS)
   Trellis effect, 205
   U
   Upstream thermoforming, 198
   199
   V
   Variotherm method, 55, 93
   94
   Variothermic mold temperature,
   93
   94
   Vegetable oils, 217
   Vertical injection-molding machine
   technology, 198
   W
   Water injection technology (WIT),
   107
   109, 150
   154
   influence of the compressibility of
   the fluid, 153
   154
   influence of the heat capacity/
   storage capacity, 150
   152
   influence of the heat transition
   coefficient and the heat
   conductivity, 152
   pressure-controlled, 115
   systems technology requirements
   for, 154
   volume flow controlled, 115
   Weak Boundary Layer Model, 167
   Weak boundary layer theory, 6
   WIT. See Water injection technology
   (WIT)
   Wittmann
   Battenfeld injectionmolding machines, 96
   97
   Wood as filling material, 223
   224
   Y
   Young’s modulus, 70

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