provides a detailed introduction to IMR, IML, INS, IMF/AIM, respectively, comparison of advantages and disadvantages, technical description, materials, process processes, mold structure, injection molding system,
IMD classification:
IMR-Insert Molding by Roller-Film, a special roll film for Japanese film delivery device, a transfer method that combines patterns and plastics. IML-Insert Molding by Label, place the label into the mold and combine it with plastic to shoot out. INS-Insert Thermoforming-film to Molding, cut the printed film and emit it directly, or heat it into a 3D type, and embed it into the mold hole and combine it with the plastic to emit it. IMF-Insert Molding by Sliced-film, like INS, the name is not unified. AIM-Rohm, a German Degussa Group, produces PMMA materials and is used in IMD technology. IMR VS IML (IMF, INS, AIM)
IMR Technical Description: Given that some current methods produced by multi-layer processing methods have high defect rates and cannot cope with multi-color requirements, if the manual operation process is complicated: injection molding → covering the protective layer → electroplating → spray painting → wipe → coloring (metaprint) → removal of the protective layer → pasting the adhesive layer Therefore, it is necessary to seek new methods that can reduce production costs. 1. Reduce the original production process and reduce costs. 2. Reduce the defect rate and reduce production costs. 3. A method that can further improve the appearance texture. 4. A working method that can achieve better weathering conditions. 5. A better environmentally friendly method can be achieved. IMR foil film: The gasket substrate depends on the surface curvature and expansion ratio of the mold. Different substrates need to be selected to cooperate with the IMD process
.
IMR molding process introduction
IMR mold structure introduction
Mold both sides need to be heated, and the injection molding gate should be installed on the fixed mold side IMR injection molding system
Four important injection molding system components: transfer foil in-mold, transfer foil locator, injection molding machine edge barrel and injection nozzle, injection mold
Related product applications:
INS Technical description: Original INS It is used to assist in primary molding injection molding (IMD), but with the demand for 3D stereoscopic decoration, today's INS technology is deeply loved by major European manufacturers in the automotive industry (Dual B AUDI). INS is to put the plastic part to be decorated into a three-dimensional mold, and then put the finished product into another mold for injection and molding. There is no film technology that can reach the deformation stage of in-mold casting INS. The film portion may be decorated on a complete surface or part of the object. INS process steps: 1. INS film → New technology thermal transfer film materials. 2. The process of heating molding → Use molds to change the film into a solid shape. Can be cross-used or merged separately...it depends entirely on the Case conditions. 3. Cut into inserts → Cut off the edges of the finished INS film. 4. Injection molding → Put it into the injection machine for injection molding (adequate ductility and elasticity are important). Advantages of INS process: 1. Save about 20% of injection materials each time. 2. It is a dry and easy decoration making process. 3. Only need to produce additional cutting and heating molding processes. 4. The decorative pattern design of the surface can be easily and at any time. 5. Several injection points can be selected. 6. Because of the luster of the film surface (Hard Code), the surface of the object is not required to be wiped after injection. 7. Both the moisture bubble point and the sunken area (shrinkage) can be covered. 8. Have good edge decoration. 9. The distortions and defects of the design can be easily identified before being shot out. 10. The surface structure in the injection mold can be clearly displayed in INS
Other decorative effects: for the same mold, just replace the surface material (INS Advantages)
related product applications:
Application of Imd in automotive parts:
IMF technical description: Given that the appearance and color of the existing mobile phone LENS is on the back, if the shape is slightly curved, the overall feeling cannot be changed with the curvature, and the appearance is naturally slightly flat and unchanged. Now, the printed film can be directly shot and molded to achieve the change of diversity, and will not be limited by the plane of the printing, and it can also solve the problem of curvature printing at the same time.
provides a detailed introduction to IMR, IML, INS, IMF/AIM, respectively, comparison of advantages and disadvantages, technical description, materials, process processes, mold structure, injection molding system,
IMD classification:
IMR-Insert Molding by Roller-Film, a special roll film for Japanese film delivery device, a transfer method that combines patterns and plastics. IML-Insert Molding by Label, place the label into the mold and combine it with plastic to shoot out. INS-Insert Thermoforming-film to Molding, cut the printed film and emit it directly, or heat it into a 3D type, and embed it into the mold hole and combine it with the plastic to emit it. IMF-Insert Molding by Sliced-film, like INS, the name is not unified. AIM-Rohm, a German Degussa Group, produces PMMA materials and is used in IMD technology. IMR VS IML (IMF, INS, AIM)
IMR Technical Description: Given that some current methods produced by multi-layer processing methods have high defect rates and cannot cope with multi-color requirements, if the manual operation process is complicated: injection molding → covering the protective layer → electroplating → spray painting → wipe → coloring (metaprint) → removal of the protective layer → pasting the adhesive layer Therefore, it is necessary to seek new methods that can reduce production costs. 1. Reduce the original production process and reduce costs. 2. Reduce the defect rate and reduce production costs. 3. A method that can further improve the appearance texture. 4. A working method that can achieve better weathering conditions. 5. A better environmentally friendly method can be achieved. IMR foil film: The gasket substrate depends on the surface curvature and expansion ratio of the mold. Different substrates need to be selected to cooperate with the IMD process
.
IMR molding process introduction
IMR mold structure introduction
Mold both sides need to be heated, and the injection molding gate should be installed on the fixed mold side IMR injection molding system
Four important injection molding system components: transfer foil in-mold, transfer foil locator, injection molding machine edge barrel and injection nozzle, injection mold
Related product applications:
INS Technical description: Original INS It is used to assist in primary molding injection molding (IMD), but with the demand for 3D stereoscopic decoration, today's INS technology is deeply loved by major European manufacturers in the automotive industry (Dual B AUDI). INS is to put the plastic part to be decorated into a three-dimensional mold, and then put the finished product into another mold for injection and molding. There is no film technology that can reach the deformation stage of in-mold casting INS. The film portion may be decorated on a complete surface or part of the object. INS process steps: 1. INS film → New technology thermal transfer film materials. 2. The process of heating molding → Use molds to change the film into a solid shape. Can be cross-used or merged separately...it depends entirely on the Case conditions. 3. Cut into inserts → Cut off the edges of the finished INS film. 4. Injection molding → Put it into the injection machine for injection molding (adequate ductility and elasticity are important). Advantages of INS process: 1. Save about 20% of injection materials each time. 2. It is a dry and easy decoration making process. 3. Only need to produce additional cutting and heating molding processes. 4. The decorative pattern design of the surface can be easily and at any time. 5. Several injection points can be selected. 6. Because of the luster of the film surface (Hard Code), the surface of the object is not required to be wiped after injection. 7. Both the moisture bubble point and the sunken area (shrinkage) can be covered. 8. Have good edge decoration. 9. The distortions and defects of the design can be easily identified before being shot out. 10. The surface structure in the injection mold can be clearly displayed in INS
Other decorative effects: for the same mold, just replace the surface material (INS Advantages)
related product applications:
Application of Imd in automotive parts:
IMF technical description: Given that the appearance and color of the existing mobile phone LENS is on the back, if the shape is slightly curved, the overall feeling cannot be changed with the curvature, and the appearance is naturally slightly flat and unchanged. Now, the printed film can be directly shot and molded to achieve the change of diversity, and will not be limited by the plane of the printing, and it can also solve the problem of curvature printing at the same time.Advantages: 1. Save about 10% of injections per time. 2. It is a dry and easy decoration making process. 3. The device only needs to have extra cutting and preheating molding when the curvature is high. 4. The decorative pattern design of the surface can be easily and at any time. 5. Several injection points can be selected. 6. Selecting the film surface (Hard Coated) can increase the surface wear resistance. 7. Both the moisture bubble point and the sunken area (shrinkage) can be covered. 8. Have good edge decoration. 9. The design distortions and defects can be easily identified before being shot out. 10. The surface structure in the injection mold can be clearly displayed on the INS film. IMF process steps:
IMF basic steps are film printing → film forming → film punching → injection molding. As shown in the figure below, the
IMF process is developed based on the popular trends of mobile phone shells and 3D color patterns. It integrates three materials (film, ink, plastic), which must be carried out through insert molding. Another method of surface hardness of
IMF is the AIM (Acrylic Insert Molding) process, which is painted with acrylic series inks by screen printing, and then extruded on the PMMA film (PLEXIGLAS?99524). This film and its pattern are printed via IMF on the PMMA mobile phone display screen or housing (PLEXIGLAS? zk5BR or zk5HF plastic) during injection molding. Selection of
IMF film: Acrylic? Use PMMA film with 92% better optical characteristics. ?Example: PLEXIGLAS of R?hm Rome Company? 99524 (0.175mm) Polycarbonate ?Use PC film with 88% optical characteristics. ?Example1: LEXAN of Strange (GE)? OQ92S or HP-92S (0.175mm) ?Example2: DE-1-1 Comparison of common IMF films (plastics)
IMF printing
screen printing will show more than 50 independent variable patterns, but there is only one IMD product, and they must be controlled! - Complete printing ink, especially silver or special effects. -The state of the art machine. - Qualified working ability. - Sufficient process parameter control. -The mutual influence between cognitive drawings, printing and IMD processes. Combination is the largest product stability. Screen printing IMD is suitable for the following two types for the market: 1. Integration of high-tech product labeling, inventory catalog technology, scratch resistance 2. Changeable products, with elastic product advantages, variable design, small and medium-sized products. Selection of IMF ink
:
-Pr?ll Noricryl? 090 and 097 series inks?Germany→Pr?ll Noricryl series inks produced? Solvent-based AC inks designed for screen printing and transfer. -Marabu Maramold? MACR series inks? Germany → Manufactured by Marabu ? Suitable for plastic products, SR-057 series inks. - Japan IPS series inks? Japan → Imperial Ink Manufacturing Co., Ltd. (Agent from Xinfeng Printing Materials Co., Ltd.). ?It has heat resistance after press-extension molding, and PC inks include IPS and INS series inks. Adhesion of HTR inks of Pr?ll to plastics Comparison of different plastics Resin Resin Resin Temperature Adhesion to HTR PC 280 - 300 °C PC/ABS 240 - 260 °C ( )* PMMA 220 - 260 °C ABS 220 - 240 °C - ( )* PS 200 °C - (-)* PA 240 - 260 °C - ( )* TPU 190 - 200 °C - are the temperature and chemical characteristics?Q factors. -Pr?ll Ink Unusability: Noricryl → PMMA Noriphan HTR → PC Noriphan N2K → PC Adjust printing viscosity (Viscosity) – Select diluent for dilution Select diluent (thinner) to control evaporation
HTR diluent (thinner) can be neutralized to meet the required conditions
drying precautions - Stack after drying
Maximum conveyor belt speed depends on the type of diluent used. Improve drying: Increase air circulation or decrease the conveyor belt speed.
Ink Relative to Plastic Temperature
Ink Relative to Film Thickness
IMF Printing Notes: -Tear off the printing surface protective film that cuts the film before printing. If there are reinforced surfaces and non-reinforced surfaces, pay attention to the front and back surfaces, as the reinforced surfaces are smoother. - If the tear-off protective film is an electrostatic film, do not use it again after tearing it off to avoid the adhesion of static electricity and causing troubles in subsequent processing.- The film will shrink when it is cold after baking, so when it is printed and stacked before baking, you should use a press strip to flatten the film to avoid touching the ink. - The baking temperature and time of the ink must be achieved according to the characteristics, otherwise there will be ink flushing. - After baking, the film has a high temperature and is very static. It is necessary to prevent dust from adhering when storing. It is best to use an electrostatic fan to blow it to prevent dust from adhering. - The window and printing area prevent touching of plain hands to avoid affecting quality. - Check whether there are any bad products for printing. If there are any, mark them and remove them after the printing. - If you want to combine different plastics (such as PCAC), you should use bonding glue. The bonding glue should be sufficient. Be careful not to use the mesh too small to avoid insufficient glue and reduce adhesion. -The baking temperature of the bonding glue does not need to be very high, as long as 65℃ is about 20~30 minutes. - The choice of ink should be able to withstand high temperatures, otherwise the high temperature will cause the ink to deform when it is emitted. - The tension of the mesh board should be as consistent as possible, and the pressure of the scraper should be as consistent as possible, otherwise there will be problems of inaccurate fittings. IMF Printing Network
IMF Punching: Issues that should be noted when using the CCD computer automatic positioning system
IMF Punching: - The purpose of drilling is to use the positioning PIN to be used in subsequent processing, so the accuracy of the positioning hole must be very high. - The film should be flat when drilling, which can increase the CCD optical focus recognition ability. - The CCD cross positioning position should be in the circular hole. -When there is a burr after punching, it means that the drill bit has been worn out. It is best to replace it with a new one to improve positioning accuracy. -The hole-punched picture should be matched with printing. It is best to choose a color system with a larger pair of light and dark to improve optical vision recognition ability. Film molding
cold bend - High yield has accurate image positioning. - Reduce the cost of treatment tools. -Reduce heat loss of ink or film substrate. - The treatment tool has a long lifespan. - The film does not need to be completely dried.
Hot bend?? Drying: ?? The rolled film must be dried before hot bend. ?? Moisture will cause blisters and adverse development. ?? You can use a hot air circulation oven to set the temperature at 120℃, place horizontally or directly at a distance of 25mm, and do not need to be re-dryed after baking for 4 hours. ?? Take LEXAN as an example: ?? 0.25mm=15 minutes. ?? 0.38-0.51mm=20 minutes. ?? 0.64-0.76mm=30 minutes. ?? Long ovens should have a minimum of four times the bending state. For example, 61x61cm bending state will require a 244cm long tunnel oven, both upper and lower must be heated. Example: Bayfol? Film Forming Process Noriphan? HTR printed on film (Makrofol?/Bayfol?) can be bent and extended toward the same as a film that has not been printed. ? Thermoforming - Heating film allows stretching and bending ? Mechanic Methods - Cold film: higher pressure to ink ? High Pressure - Heating the film slightly to make the design of high-pressure
molding dies ? Thermoforming parts will be removed from the mold at one time and cooled into the dimensions. ?This shrinkage is predictable and the mold size must be calculated to ensure that the finished parts are in compliance with the size. ?When the finished film part size is critical, the mold operating temperature must be taken into account relatively. ?Take LEXAN film as an example: the shrinkage ratio indicated is about 0.5~0.9% (such as: .005~.009 inches per inch), and the parameters are processed according to the pre-bending. ?To estimate the accurate mold size, the mold material temperature expansion coefficient must be subtracted from the shrinkage amount of film at an operating temperature of 120°C.
Draft Angles for Vacuum Forming? It is recommended to have an angle depth of 5~7 degrees, which is used to help parts to be separated from the male model. ?The female mold needs a small angle (1~2 degrees only). ?To achieve maximum product efficiency and promote appropriate thickness distribution, all mold angles must have a minimum radius of 1 times the material thickness, the larger the radius, the better. ?Write details of parts and parts of the mold to all levels of vacuum dissipation is required. ?A small vacuum groove is formed with various iron blocks of different shapes, with a hole of 0.02" (0.51mm) per 1/2" (13mm). ? Use 500 or 600grit gold steel sandpaper to smooth out all mold surfaces to facilitate vacuum grip. Notes on IMF punching: - Put the film with the positioning holes in the punching mold positioning PIN to punch out the shape we want. -After the molding, the bad products will be recorded and the scrapping procedure will be processed. - The finished products with good punching shapes are placed in the clamping belt one by one and transferred to the next station.- Pay attention to whether there are large burrs in finished products of punching. Sometimes the mold is injured or the service life has expired. - Pay attention to whether there is oil pollution after the finished product after the molding is damaged, and keep the film clean at all times.
Injector selection: ?IMD can be done on a general injector. ?The total amount of glue injection and the total projection area on the equipment are two decisive considerations. ?The best result is typically represented when the total injection volume (cavities, plus, runners, sprues) is equal to 30~80% of the total equipment capacity. ? Very small shots in large barrels can be constructed without the need for long plastic presence that causes degradation of the plastic. ?The 3~5 tons clamping pressure can provide a projected area of each square inch to avoid flashing of the part. ?Wall thickness, mold flow length and molding parameters will represent the actual tonnage requirements that determine the actual tonnage. ?Most traditional barrels and screw designs are used in engineering plastics and are also compatible with IMD. The relationship between the mold clamping pressure affects the thickness of the film and the part
Injection pressure affects the relationship between the thickness of the film and the part
IMF issues to be noted: - Before ejecting, the protective film on the film must be tear off. At this time, attention must be paid to the dust attachment problem of static electricity. Before loading the film into the mold, the static electricity must be blown off and then loaded to avoid dust being wrapped into the product and causing bad appearance. - Since static electricity cannot be attached to the injection mold after being eliminated, a vertical injection opportunity is more suitable. If there is a positioning PIN fixed film, a horizontal machine is also possible. To facilitate the operation of the load film, the vertical one is also more convenient. -Wear gloves when tearing the film, and do not touch the non-printing area. - Before loading the mold holes, check whether the film has any defects. If there is, remove it. - The yield rate is determined by the environment around the injection, so the best working environment must be maintained at any time during operation to ensure production quality. - If there is a flushing ink found out of the injection port, it is generally the printing ink that has not completely dried. It should be immediately reported to improve the printing. IMF injection glue port design: Method 1
Method 2
IMF glue port ink
glue channel form: tunnel gate? The reverse side injection of shooting resin is completed from the fixed edge of the model and the movable edge and the surface of the back part filled. ?The pouring system and the glue path system must be extended outside this separate line to the movable edge of the mold, allowing the resin to flow continuously to the back side of the film
.
glue channel form: cashew gate? When using IMD technology with a variety of heat or a direct casting system, the reverse ejection is suitable. ?This system injects and ejects and occurs on the fixed edge of the mold
.
glue channel form: the glue channel indirect runner to gate approach? The potential of using a single glue channel to cause wrinkling of the film is minimized whenever possible. ? Keep the length of the glue mouth surface as short as possible. ?A impact glue port can ensure the flow in and avoid spraying. ?Find the glue port at right angles to minimize spraying
glue port form: Edge gate ? The film extends over the area that promotes consistent glue port flow to the correct edge of the film.
glue mouth form: Flash gate? The glue is fed parallel to the surface of the rubber inlet. The surface is increased and the flow is fast, the average point heat effect is small, the time is short, and the thermal shock can be improved. ?The glue removal surface is large and the processing difficulty is high.
glue mouth form: Fan gate? Fan-shaped glue mouth can reduce thermal effects, and the glue mouth can be moderately corrected according to the size of the product to meet the external closing quality. ?Generally, this method is used more in side adhesive injection.The effect of the glue mouth form against the ink (wash out)
Glue channel form: Differences in shape The smoother the glue channel, the more mold flow is, the situation is not caused. The square shape on the left is the worse shape, and the right is better, as shown in the figure below
:
NISSHA IMD Shape inspection manual - Phone handset window organization product peripheral shape (Parting Line) - How to determine the peripheral separation line (PL) - Determination value
hole separation line (Hold Parting Line) - Determination value
-Trough shape-When vapor phase deposition is suitable for grooves, microcracks that are likely to occur due to metal treatment. Therefore, a groove depth of 0.2 mm is recommended. The following basic values are adopted in the form of grooves. Groove depth: 0.2mm, groove distortion angle: 110 degrees, groove R: 0.15mm, bottom face length: 0.5mm
IMF Mechanism design (I)
When the groove (art line) needs to be evaporated, fine cracks will occur in the evaporated layer metal. Therefore, the groove depth is recommended to be 0.2mm, the groove slope is 110°, the groove R angle is 0.15mm, and the bottom surface width is 0.5mm, as shown in the figure. IMF mechanism design (II)
If there is a hole design in the groove, the total depth can be increased by 0.35mm (originally 0.2mm), the groove depth of the outer diameter reference line of the groove section face 0.2mm groove and vertical section face hole outer diameter reference line film transfer surface groove depth: maximum 0.2mm hole depth: 0.15mm surface displacement 0.15mm non-porous design transfer surface hole design transfer surface hole design The groove depth of the non-porous design is 0.2mm IMF mechanism design (II)
1. If PMMA or ABS is used and the wall thickness is less than 1.2mm, using Pin Gate will cause ink spraying problems. 2. If the wall thickness is less than 1.2mm, in order to prevent ink spraying problems, a dome with a diameter of φ4.0mm and a height of 0.15 to 0.3mm can be designed as the base, and then the gate is placed on it. In addition, using the Pin Gate pouring method, generally a 1.0mm (Max.) material head will remain. 3. The runner diameter is generally designed as φ1.2mm IMF mechanism design (IV)
IMF mechanism design (V)
IMF product thickness: the uniform thickness is the best, so as to avoid the occurrence of shrinkage marks, and the optimal uniform thickness is recommended to be 1.5mm. In addition, it must be noted that the average thickness of different plastic materials must not be lower than the following specifications: PMMAABS: Average 1.2mm PCPC ABS: Average 1.5mm other forms of IMF
[Single Film System - First Side] The ink is on the outside and the film is on the inside. It is bonded to the film when it is injected. For example, the PC film and PMMA plastic can also be bonded, but the bondability is poor, but it can be passed through constant temperature and humidity (55℃, 93%RH, 96hr). NOKIA Vespa is an example
[Single Film System-Second Side]
ink inside; the film is on the outside, and the plastic and the ink are bonded when it is ejected. At this time, if you use PC film and use PC series ink, if you are not in good condition with PMMA, you should add a bonding glue as the interface, otherwise the film will be defiled. If you choose AC-friendly ink, you should consider whether the adhesion to the PC is good, and whether there is a flushing ink? Sony Ericsson 2115 is an example, as shown in the figure below: Sony Ericsson T-100 (2115) communication mobile phone LENS
Motorola (i95cl) communication mobile phone LENS
light treasure communication mobile phone case contains LENS
pre-forming injection [Dual-membrane system-second side]
pre-forming injection using a transfer film to print IMD ink. When the second film is injected, the transfer and injection are completed together when the injection is injected. SAGEM (my X5-2) is an example of
drying precautions - drying before injection The residual solvents (residual solvents) exist after the film is printed - When the printed film is heated, the residual solvent will form bubbles. -Using NORIPHAN? HTR series ink residue solvents with greater heat resistance must be removed. - Completed parts with residual solvents will cause damage during climate testing or use.
If there is no hot bend, the final drying can be used. After printing, it is as good as after the bend!
IMF Punching: Issues that should be noted when using the CCD computer automatic positioning system
IMF Punching: - The purpose of drilling is to use the positioning PIN to be used in subsequent processing, so the accuracy of the positioning hole must be very high. - The film should be flat when drilling, which can increase the CCD optical focus recognition ability. - The CCD cross positioning position should be in the circular hole. -When there is a burr after punching, it means that the drill bit has been worn out. It is best to replace it with a new one to improve positioning accuracy. -The hole-punched picture should be matched with printing. It is best to choose a color system with a larger pair of light and dark to improve optical vision recognition ability. Film molding
cold bend - High yield has accurate image positioning. - Reduce the cost of treatment tools. -Reduce heat loss of ink or film substrate. - The treatment tool has a long lifespan. - The film does not need to be completely dried.
Hot bend?? Drying: ?? The rolled film must be dried before hot bend. ?? Moisture will cause blisters and adverse development. ?? You can use a hot air circulation oven to set the temperature at 120℃, place horizontally or directly at a distance of 25mm, and do not need to be re-dryed after baking for 4 hours. ?? Take LEXAN as an example: ?? 0.25mm=15 minutes. ?? 0.38-0.51mm=20 minutes. ?? 0.64-0.76mm=30 minutes. ?? Long ovens should have a minimum of four times the bending state. For example, 61x61cm bending state will require a 244cm long tunnel oven, both upper and lower must be heated. Example: Bayfol? Film Forming Process Noriphan? HTR printed on film (Makrofol?/Bayfol?) can be bent and extended toward the same as a film that has not been printed. ? Thermoforming - Heating film allows stretching and bending ? Mechanic Methods - Cold film: higher pressure to ink ? High Pressure - Heating the film slightly to make the design of high-pressure
molding dies ? Thermoforming parts will be removed from the mold at one time and cooled into the dimensions. ?This shrinkage is predictable and the mold size must be calculated to ensure that the finished parts are in compliance with the size. ?When the finished film part size is critical, the mold operating temperature must be taken into account relatively. ?Take LEXAN film as an example: the shrinkage ratio indicated is about 0.5~0.9% (such as: .005~.009 inches per inch), and the parameters are processed according to the pre-bending. ?To estimate the accurate mold size, the mold material temperature expansion coefficient must be subtracted from the shrinkage amount of film at an operating temperature of 120°C.
Draft Angles for Vacuum Forming? It is recommended to have an angle depth of 5~7 degrees, which is used to help parts to be separated from the male model. ?The female mold needs a small angle (1~2 degrees only). ?To achieve maximum product efficiency and promote appropriate thickness distribution, all mold angles must have a minimum radius of 1 times the material thickness, the larger the radius, the better. ?Write details of parts and parts of the mold to all levels of vacuum dissipation is required. ?A small vacuum groove is formed with various iron blocks of different shapes, with a hole of 0.02" (0.51mm) per 1/2" (13mm). ? Use 500 or 600grit gold steel sandpaper to smooth out all mold surfaces to facilitate vacuum grip. Notes on IMF punching: - Put the film with the positioning holes in the punching mold positioning PIN to punch out the shape we want. -After the molding, the bad products will be recorded and the scrapping procedure will be processed. - The finished products with good punching shapes are placed in the clamping belt one by one and transferred to the next station.- Pay attention to whether there are large burrs in finished products of punching. Sometimes the mold is injured or the service life has expired. - Pay attention to whether there is oil pollution after the finished product after the molding is damaged, and keep the film clean at all times.
Injector selection: ?IMD can be done on a general injector. ?The total amount of glue injection and the total projection area on the equipment are two decisive considerations. ?The best result is typically represented when the total injection volume (cavities, plus, runners, sprues) is equal to 30~80% of the total equipment capacity. ? Very small shots in large barrels can be constructed without the need for long plastic presence that causes degradation of the plastic. ?The 3~5 tons clamping pressure can provide a projected area of each square inch to avoid flashing of the part. ?Wall thickness, mold flow length and molding parameters will represent the actual tonnage requirements that determine the actual tonnage. ?Most traditional barrels and screw designs are used in engineering plastics and are also compatible with IMD. The relationship between the mold clamping pressure affects the thickness of the film and the part
Injection pressure affects the relationship between the thickness of the film and the part
IMF issues to be noted: - Before ejecting, the protective film on the film must be tear off. At this time, attention must be paid to the dust attachment problem of static electricity. Before loading the film into the mold, the static electricity must be blown off and then loaded to avoid dust being wrapped into the product and causing bad appearance. - Since static electricity cannot be attached to the injection mold after being eliminated, a vertical injection opportunity is more suitable. If there is a positioning PIN fixed film, a horizontal machine is also possible. To facilitate the operation of the load film, the vertical one is also more convenient. -Wear gloves when tearing the film, and do not touch the non-printing area. - Before loading the mold holes, check whether the film has any defects. If there is, remove it. - The yield rate is determined by the environment around the injection, so the best working environment must be maintained at any time during operation to ensure production quality. - If there is a flushing ink found out of the injection port, it is generally the printing ink that has not completely dried. It should be immediately reported to improve the printing. IMF injection glue port design: Method 1
Method 2
IMF glue port ink
glue channel form: tunnel gate? The reverse side injection of shooting resin is completed from the fixed edge of the model and the movable edge and the surface of the back part filled. ?The pouring system and the glue path system must be extended outside this separate line to the movable edge of the mold, allowing the resin to flow continuously to the back side of the film
.
glue channel form: cashew gate? When using IMD technology with a variety of heat or a direct casting system, the reverse ejection is suitable. ?This system injects and ejects and occurs on the fixed edge of the mold
.
glue channel form: the glue channel indirect runner to gate approach? The potential of using a single glue channel to cause wrinkling of the film is minimized whenever possible. ? Keep the length of the glue mouth surface as short as possible. ?A impact glue port can ensure the flow in and avoid spraying. ?Find the glue port at right angles to minimize spraying
glue port form: Edge gate ? The film extends over the area that promotes consistent glue port flow to the correct edge of the film.
glue mouth form: Flash gate? The glue is fed parallel to the surface of the rubber inlet. The surface is increased and the flow is fast, the average point heat effect is small, the time is short, and the thermal shock can be improved. ?The glue removal surface is large and the processing difficulty is high.
glue mouth form: Fan gate? Fan-shaped glue mouth can reduce thermal effects, and the glue mouth can be moderately corrected according to the size of the product to meet the external closing quality. ?Generally, this method is used more in side adhesive injection.The effect of the glue mouth form against the ink (wash out)
Glue channel form: Differences in shape The smoother the glue channel, the more mold flow is, the situation is not caused. The square shape on the left is the worse shape, and the right is better, as shown in the figure below
:
NISSHA IMD Shape inspection manual - Phone handset window organization product peripheral shape (Parting Line) - How to determine the peripheral separation line (PL) - Determination value
hole separation line (Hold Parting Line) - Determination value
-Trough shape-When vapor phase deposition is suitable for grooves, microcracks that are likely to occur due to metal treatment. Therefore, a groove depth of 0.2 mm is recommended. The following basic values are adopted in the form of grooves. Groove depth: 0.2mm, groove distortion angle: 110 degrees, groove R: 0.15mm, bottom face length: 0.5mm
IMF Mechanism design (I)
When the groove (art line) needs to be evaporated, fine cracks will occur in the evaporated layer metal. Therefore, the groove depth is recommended to be 0.2mm, the groove slope is 110°, the groove R angle is 0.15mm, and the bottom surface width is 0.5mm, as shown in the figure. IMF mechanism design (II)
If there is a hole design in the groove, the total depth can be increased by 0.35mm (originally 0.2mm), the groove depth of the outer diameter reference line of the groove section face 0.2mm groove and vertical section face hole outer diameter reference line film transfer surface groove depth: maximum 0.2mm hole depth: 0.15mm surface displacement 0.15mm non-porous design transfer surface hole design transfer surface hole design The groove depth of the non-porous design is 0.2mm IMF mechanism design (II)
1. If PMMA or ABS is used and the wall thickness is less than 1.2mm, using Pin Gate will cause ink spraying problems. 2. If the wall thickness is less than 1.2mm, in order to prevent ink spraying problems, a dome with a diameter of φ4.0mm and a height of 0.15 to 0.3mm can be designed as the base, and then the gate is placed on it. In addition, using the Pin Gate pouring method, generally a 1.0mm (Max.) material head will remain. 3. The runner diameter is generally designed as φ1.2mm IMF mechanism design (IV)
IMF mechanism design (V)
IMF product thickness: the uniform thickness is the best, so as to avoid the occurrence of shrinkage marks, and the optimal uniform thickness is recommended to be 1.5mm. In addition, it must be noted that the average thickness of different plastic materials must not be lower than the following specifications: PMMAABS: Average 1.2mm PCPC ABS: Average 1.5mm other forms of IMF
[Single Film System - First Side] The ink is on the outside and the film is on the inside. It is bonded to the film when it is injected. For example, the PC film and PMMA plastic can also be bonded, but the bondability is poor, but it can be passed through constant temperature and humidity (55℃, 93%RH, 96hr). NOKIA Vespa is an example
[Single Film System-Second Side]
ink inside; the film is on the outside, and the plastic and the ink are bonded when it is ejected. At this time, if you use PC film and use PC series ink, if you are not in good condition with PMMA, you should add a bonding glue as the interface, otherwise the film will be defiled. If you choose AC-friendly ink, you should consider whether the adhesion to the PC is good, and whether there is a flushing ink? Sony Ericsson 2115 is an example, as shown in the figure below: Sony Ericsson T-100 (2115) communication mobile phone LENS
Motorola (i95cl) communication mobile phone LENS
light treasure communication mobile phone case contains LENS
pre-forming injection [Dual-membrane system-second side]
pre-forming injection using a transfer film to print IMD ink. When the second film is injected, the transfer and injection are completed together when the injection is injected. SAGEM (my X5-2) is an example of
drying precautions - drying before injection The residual solvents (residual solvents) exist after the film is printed - When the printed film is heated, the residual solvent will form bubbles. -Using NORIPHAN? HTR series ink residue solvents with greater heat resistance must be removed. - Completed parts with residual solvents will cause damage during climate testing or use.
If there is no hot bend, the final drying can be used. After printing, it is as good as after the bend!
