模内覆膜装饰制品质量缺陷影响因素分析
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摘要
随着人们对产品外观表面质量的要求越来越高,模内覆膜装饰技术逐渐成为表面装饰技术的热点,已广泛地应用于对产品外观要求较高的消费性电子产品及汽车内饰件等产品上。根据国内外模内覆膜装饰技术的发展现状,分析了薄膜印刷、薄膜热压成型及注塑成型几个重要过程对模内覆膜装饰制品质量的影响。针对产品典型质量缺陷,如冲墨、变形、分离等产生的原因进行了分析,预测了模内覆膜装饰技术未来的发展趋势。
Because the demands of surface quality of product appearance become higher and higher gradually,the hot surface decorating technology becomes the hot point. It is widely used in consumer electronics products and automotive interior parts with higher appearance requirements. According to the domestic and foreign research situation of in-mould decoration technology,several important factors which affect the quality of plastic products such as film-printing process,film-thermoforming process,and injection process are analyzed in this paper. In addition,some typical defects such as the ink wash-off,warpage and separation in the injection molded parts are reviewed,and the future development trend of in-mould decoration technology is predicted.
Because the demands of surface quality of product appearance become higher and higher gradually,the hot surface decorating technology becomes the hot point. It is widely used in consumer electronics products and automotive interior parts with higher appearance requirements. According to the domestic and foreign research situation of in-mould decoration technology,several important factors which affect the quality of plastic products such as film-printing process,film-thermoforming process,and injection process are analyzed in this paper. In addition,some typical defects such as the ink wash-off,warpage and separation in the injection molded parts are reviewed,and the future development trend of in-mould decoration technology is predicted.
引文
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[6]郭珊珊,钱军浩.基于IMD技术的印制质量分析[J].包装工程,2009(6):77-79.
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[9]吴跃坚,边彬辉.模内镶件注射薄膜拉深成型工艺影响因素[J].模具工业,2010(8):42-45,50.
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[11]Gugyong Kim,Kwango Lee,Sungsu Kang.Prediction of the Film Thickness Distribution and Pattern Change During Film Insert Thermoforming[J].Polymer Engineering and Science,2009,49(11):2195-2203.
[12]陈松茂,阮锋,蔡考群.模内镶件注塑膜片的粘弹性本构模型[J].华南理工大学学报(自然科学版),2009,37(8):24-28.
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[15]Shia-Chung Chen,Shih-Tsun Huang,Ming-Chung Lin,et al.Study on the thermoforming of PC films used for in-mold decoration[J].International Communications in Heat and Mass Transfer,2008,35(8):967-973.
[16]边彬辉,阮锋,陈松茂,等.IMD薄膜拉深热成型工艺的开发[J].塑料工业,2009,37(1):26-29,37.
[17]阮锋,陈松茂,边彬辉,等.模内镶件膜片拉胀复合热压成型工艺的试验研究[J].塑料工业,2008,36(7):28-30,41.
[18]Hong-Seok Park,Xuan-Phuong Dang.Development of a retention mechanism for minimizing defective overlap in film-insert molding[C]//Strategic Technology(IFOST),2010 International Forum on,2010:161-166.
[19]刘人豪,李佳韦,张庆伟,等.探讨射出压缩成型对IMD薄膜表面微结构之影响[C]//第七届先进成型与材料加工技术国际研讨会,武汉:华中科技大学,2010:8-11.
[20]Hwa Jin Oh,Young Seok Song,Sung Ho Kim,et al.Fluid–structure interaction analysis on the film wrinkling problem of a film insert molded part[J].Polymer Engineering&Science,2011,51(4):812-818.
[21]贾玉龙.汽车内饰IMD成型工艺研究[D].哈尔滨:哈尔滨工业大学,2012.
[22]S.J.Liu,C.M.Hsu,P.W.Chang.Parameters Affecting the Ink Wash-off in In-mold Decoration of Injection Molded Parts[J].International Polymer Processing,2012,27(2):224-230.
[23]Y.W.Leong,S.Yamaguchi,M.Mizoguchi,et al.The effect of molding conditions on mechanical and morphological properties at the interface of film insert injection molded polypropylenefilm/polypropylene matrix[J].Polymer Engineering&Science,2004,44(12):2327-2334.
[24]S.Yamaguchi,Y.W.Leong,T.Tsujii,et al.Effect of crystallization and interface formation mechanism on mechanical properties of film-insert injection-molded poly(propylene)(PP)film/PP substrate[J].Journal of Applied Polymer Science,2005,98(1):294-301.
[25]Y.W.Leong,U.S.Ishiaku,M.Kotaki,et al.Interfacial characteristics of film insert molded polycarbonate film/polycarbonateacrylonitrile-butadiene-styrene substrate,part 1:Influence of substrate molecular weight and film thickness[J].Polymer Engineering&Science,2006,46(12):1674-1683.
[26]智川,兀旦晖.IMD产质量量的工艺控制[J].丝网印刷,2005(6):45-48.
[27]王薇莉,胡在京,陈利民.采用模内装饰技术的手机面板注塑模具设计[J].塑料,2009(2):101-103.
[28]蔡考群,尹高喜,唐均华.模内装饰注塑成型方法及薄膜热压成型模具:中国,101347988[P].2009-1-21.
[29]D Lee,WA Chen,TW Huang,et al.Factors Influencing the Warpage in In-Mold Decoration Injection Molded Composites[EB/OL].2013-1-1.http://www.moldex3d.com.
[30]Seong Yun Kim,Seung Hwan Lee,Soo Jin Baek,et al.Thermoviscoelastic Behavior of Film-Insert-Molded Parts Prepared under Various Processing Conditions[J].Macromolecular Materials and Engineering,2008,293(12):969-978.
[31]Hwa Jin Oh,Young Seok Song,Seung Hwan Lee,et al.Development of warpage and residual stresses in film insert molded parts[J].Polymer Engineering&Science,2009,49(7):1389-1399.
[32]Soo Jin Baek,Seong Yun Kim,Seung Hwan Lee,et al.Effect of processing conditions on warpage of film insert molded parts[J].Fibers Polym,2008,9(6):747-754.
[33]Soo Jin Baek,Seong Yun Kim,JaeRyoun Youn,et al.Warpage and mechanical properties of film insert molded parts with composite substrate[J].Fibers Polym,2011,12(7):927-931.
[34]Seong Yun Kim,Jin Young Kim,Sung Ho Kim,et al.Numerical flow analysis on warpage of film insert molded parts with fiber reinforced polymer substrate[J].Korea-Australia Rheology Journal,2010,22(3):179-186.
[35]Jin Young Kim,Seong Yun Kim,Young Seok Song,et al.Relationship between the crystallization behavior and the warpage of film-insert-molded parts[J].Journal of Applied Polymer Science,2011,120(3):1539-1546.
[36]薛丹.注塑模内薄膜对冷却过程的影响[D].武汉:华中科技大学,2009.
[37]石宪章,申长雨,赵振峰.注塑冷却分析模内复膜数学模型建模[J].化工学报,2006(1):181-185.
[38]Shia-Chung Chen,Hai-Mei Li,Shih-Tsun Huang,et al.Effect of decoration film on mold surface temperature during in-mold decoration injection molding process[J].International Communications in Heat and Mass Transfer,2010,37(5):501-505.
[39]陈惠俐,陈夏宗,王膺杰,等.IMD薄膜滞热在射出成型制程研究[C]//第五届两岸三地先进成型技术与材料加工研讨会论文集[C],北京:世界塑料工程学会,2008:46-49.
[40]Seong Yun Kim,Jung Tae Lee,Jin Young Kim,et al.Effects of film and substrate dimensions on warpage of film insert molded parts[J].Polymer Engineering&Science,2010,50(6):1205-1213.
[41]Patcharee Larpsuriyakul,Hans-Gerhard Fritz.Warpage and Countermeasure for Injection-Molded In-Mold Labeling Parts[J].Polymer Engineering and Science,2011,51(3):411-418.
[42]Hui-Li Chen,Shia-Chung Chen,Won-Hsion Liao,et al.Effects of insert film on asymmetric mold temperature and associated part warpage during in-mold decoration injection molding of PP parts[J].International Communications in Heat and Mass Transfer,2013,41(0):34-40.
[43]智川,赵晓静.IMD技术油墨附着性的分析与研究[J].无锡:印刷世界,2005(7):54-56.
[44]郭珊珊.基于IMD技术的印刷质量控制研究[D].江南大学,2009.
[45]欧会全.IMD模内装饰油墨[J].丝网印刷,2012(2):12-15.
[46]Y.W.Leong,M.Kotaki,H.Hamada.Effects of the molecular orientation and crystallization on film–substrate interfacial adhesion in poly(ethylene terephthalate)film-insert moldings[J].Journal of Applied Polymer Science,2007,104(4):2100-2107.
[47]Y.W.Leong,H.Hamada.Interfacial Characteristics of Film Insert Moldings Consisting of Semicrystalline and Amorphous Polymers[J].International Polymer Processing,2008,23(2):183-191.
[2]周煜涵.IMD技术及其在汽车中的应用[J].江苏科技信息,2012(6):52-54.
[3]王崇高.注塑成型表面装饰技术的研究和应用[J].塑料工业,2004(5):52-54.
[4]龚玉宏.塑料产品表面装饰新工艺——模内复膜[J].塑料工业,2005(11):1-3.
[5]吴张永.FIM/IMD技术中油墨的设计与选择[J].丝网印刷,2007(10):24-28.
[6]郭珊珊,钱军浩.基于IMD技术的印制质量分析[J].包装工程,2009(6):77-79.
[7]梁伟标.IMD技术与应用[J].丝网印刷,2008(11):15-17.
[8]边彬辉.聚碳酸酯热拉深工艺及在IMD的应用研究[D].广州:华南理工大学,2009.
[9]吴跃坚,边彬辉.模内镶件注射薄膜拉深成型工艺影响因素[J].模具工业,2010(8):42-45,50.
[10]Chen S M,Ruan F,Zhang Z J,et al.Pre-drawing and air-bulging technology used in the in-mould-decoration thermoforming process for complex plastic products[M].Advanced Design and Manufacture to Gain a Competitive Edge.Springer London,2008:835-844.
[11]Gugyong Kim,Kwango Lee,Sungsu Kang.Prediction of the Film Thickness Distribution and Pattern Change During Film Insert Thermoforming[J].Polymer Engineering and Science,2009,49(11):2195-2203.
[12]陈松茂,阮锋,蔡考群.模内镶件注塑膜片的粘弹性本构模型[J].华南理工大学学报(自然科学版),2009,37(8):24-28.
[13]陈松茂,阮锋,蔡考群.模内镶件注塑膜片材料力学性能研究[J].现代制造工程,2009(5):79-82.
[14]Sung Ho Kim,Seong Yun Kim,Seung Hwan Lee,et al.Residual stresses and thermoviscoelastic deformation of laminated film prepared for film insert molding[J].Polymer Engineering&Science,2012,52(5):1121-1127.
[15]Shia-Chung Chen,Shih-Tsun Huang,Ming-Chung Lin,et al.Study on the thermoforming of PC films used for in-mold decoration[J].International Communications in Heat and Mass Transfer,2008,35(8):967-973.
[16]边彬辉,阮锋,陈松茂,等.IMD薄膜拉深热成型工艺的开发[J].塑料工业,2009,37(1):26-29,37.
[17]阮锋,陈松茂,边彬辉,等.模内镶件膜片拉胀复合热压成型工艺的试验研究[J].塑料工业,2008,36(7):28-30,41.
[18]Hong-Seok Park,Xuan-Phuong Dang.Development of a retention mechanism for minimizing defective overlap in film-insert molding[C]//Strategic Technology(IFOST),2010 International Forum on,2010:161-166.
[19]刘人豪,李佳韦,张庆伟,等.探讨射出压缩成型对IMD薄膜表面微结构之影响[C]//第七届先进成型与材料加工技术国际研讨会,武汉:华中科技大学,2010:8-11.
[20]Hwa Jin Oh,Young Seok Song,Sung Ho Kim,et al.Fluid–structure interaction analysis on the film wrinkling problem of a film insert molded part[J].Polymer Engineering&Science,2011,51(4):812-818.
[21]贾玉龙.汽车内饰IMD成型工艺研究[D].哈尔滨:哈尔滨工业大学,2012.
[22]S.J.Liu,C.M.Hsu,P.W.Chang.Parameters Affecting the Ink Wash-off in In-mold Decoration of Injection Molded Parts[J].International Polymer Processing,2012,27(2):224-230.
[23]Y.W.Leong,S.Yamaguchi,M.Mizoguchi,et al.The effect of molding conditions on mechanical and morphological properties at the interface of film insert injection molded polypropylenefilm/polypropylene matrix[J].Polymer Engineering&Science,2004,44(12):2327-2334.
[24]S.Yamaguchi,Y.W.Leong,T.Tsujii,et al.Effect of crystallization and interface formation mechanism on mechanical properties of film-insert injection-molded poly(propylene)(PP)film/PP substrate[J].Journal of Applied Polymer Science,2005,98(1):294-301.
[25]Y.W.Leong,U.S.Ishiaku,M.Kotaki,et al.Interfacial characteristics of film insert molded polycarbonate film/polycarbonateacrylonitrile-butadiene-styrene substrate,part 1:Influence of substrate molecular weight and film thickness[J].Polymer Engineering&Science,2006,46(12):1674-1683.
[26]智川,兀旦晖.IMD产质量量的工艺控制[J].丝网印刷,2005(6):45-48.
[27]王薇莉,胡在京,陈利民.采用模内装饰技术的手机面板注塑模具设计[J].塑料,2009(2):101-103.
[28]蔡考群,尹高喜,唐均华.模内装饰注塑成型方法及薄膜热压成型模具:中国,101347988[P].2009-1-21.
[29]D Lee,WA Chen,TW Huang,et al.Factors Influencing the Warpage in In-Mold Decoration Injection Molded Composites[EB/OL].2013-1-1.http://www.moldex3d.com.
[30]Seong Yun Kim,Seung Hwan Lee,Soo Jin Baek,et al.Thermoviscoelastic Behavior of Film-Insert-Molded Parts Prepared under Various Processing Conditions[J].Macromolecular Materials and Engineering,2008,293(12):969-978.
[31]Hwa Jin Oh,Young Seok Song,Seung Hwan Lee,et al.Development of warpage and residual stresses in film insert molded parts[J].Polymer Engineering&Science,2009,49(7):1389-1399.
[32]Soo Jin Baek,Seong Yun Kim,Seung Hwan Lee,et al.Effect of processing conditions on warpage of film insert molded parts[J].Fibers Polym,2008,9(6):747-754.
[33]Soo Jin Baek,Seong Yun Kim,JaeRyoun Youn,et al.Warpage and mechanical properties of film insert molded parts with composite substrate[J].Fibers Polym,2011,12(7):927-931.
[34]Seong Yun Kim,Jin Young Kim,Sung Ho Kim,et al.Numerical flow analysis on warpage of film insert molded parts with fiber reinforced polymer substrate[J].Korea-Australia Rheology Journal,2010,22(3):179-186.
[35]Jin Young Kim,Seong Yun Kim,Young Seok Song,et al.Relationship between the crystallization behavior and the warpage of film-insert-molded parts[J].Journal of Applied Polymer Science,2011,120(3):1539-1546.
[36]薛丹.注塑模内薄膜对冷却过程的影响[D].武汉:华中科技大学,2009.
[37]石宪章,申长雨,赵振峰.注塑冷却分析模内复膜数学模型建模[J].化工学报,2006(1):181-185.
[38]Shia-Chung Chen,Hai-Mei Li,Shih-Tsun Huang,et al.Effect of decoration film on mold surface temperature during in-mold decoration injection molding process[J].International Communications in Heat and Mass Transfer,2010,37(5):501-505.
[39]陈惠俐,陈夏宗,王膺杰,等.IMD薄膜滞热在射出成型制程研究[C]//第五届两岸三地先进成型技术与材料加工研讨会论文集[C],北京:世界塑料工程学会,2008:46-49.
[40]Seong Yun Kim,Jung Tae Lee,Jin Young Kim,et al.Effects of film and substrate dimensions on warpage of film insert molded parts[J].Polymer Engineering&Science,2010,50(6):1205-1213.
[41]Patcharee Larpsuriyakul,Hans-Gerhard Fritz.Warpage and Countermeasure for Injection-Molded In-Mold Labeling Parts[J].Polymer Engineering and Science,2011,51(3):411-418.
[42]Hui-Li Chen,Shia-Chung Chen,Won-Hsion Liao,et al.Effects of insert film on asymmetric mold temperature and associated part warpage during in-mold decoration injection molding of PP parts[J].International Communications in Heat and Mass Transfer,2013,41(0):34-40.
[43]智川,赵晓静.IMD技术油墨附着性的分析与研究[J].无锡:印刷世界,2005(7):54-56.
[44]郭珊珊.基于IMD技术的印刷质量控制研究[D].江南大学,2009.
[45]欧会全.IMD模内装饰油墨[J].丝网印刷,2012(2):12-15.
[46]Y.W.Leong,M.Kotaki,H.Hamada.Effects of the molecular orientation and crystallization on film–substrate interfacial adhesion in poly(ethylene terephthalate)film-insert moldings[J].Journal of Applied Polymer Science,2007,104(4):2100-2107.
[47]Y.W.Leong,H.Hamada.Interfacial Characteristics of Film Insert Moldings Consisting of Semicrystalline and Amorphous Polymers[J].International Polymer Processing,2008,23(2):183-191.