Influence of Processing Conditions on the Generation of Surface Defects in a Heat-and-Cool Hybrid Injection Molding Technique for Carbon Fiber-Reinforced Thermoplastic Sheets and Development of a Suitable Mold Heated by Far-Infrared Radiation
Recently, hybrid injection molding—a type of overmolding technology in which a short carbon fiber-reinforced thermoplastic is injection molded over a compression-molded carbon fiber-reinforced thermoplastic (CFRTP) sheet—has been introduced. A heat-and-cool hybrid injection molding technique has als...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-11-01
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| Series: | Polymers |
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| Online Access: | https://www.mdpi.com/2073-4360/15/22/4437 |
| _version_ | 1797457910754705408 |
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| author | Yasuhiko Murata Ryunosuke Machiya Takuma Komori |
| author_facet | Yasuhiko Murata Ryunosuke Machiya Takuma Komori |
| author_sort | Yasuhiko Murata |
| collection | DOAJ |
| description | Recently, hybrid injection molding—a type of overmolding technology in which a short carbon fiber-reinforced thermoplastic is injection molded over a compression-molded carbon fiber-reinforced thermoplastic (CFRTP) sheet—has been introduced. A heat-and-cool hybrid injection molding technique has also been introduced for practical use. The technique yields high-quality molded products. This is achieved through the heating of the mold cavity surface to a temperature higher than the melting point of the base polymer impregnated into the carbon fiber fabric. However, few experimental analyses of the molding phenomena in heat-and-cool hybrid injection molding have been reported. In particular, the effect of the processing conditions on the transfer of the mold cavity surface shape to the CFRTP sheet has not been clarified in detail. Therefore, it has been impossible to take extensive measures when defects are generated in molded products. In this study, a mold is designed and fabricated for use with far-infrared radiation heating, a variotherm technology that is suitable for the experimental analysis of the heat-and-cool hybrid injection molding phenomenon. In particular, a mold is designed and fabricated to continuously perform the following three processes using only an injection molding machine: (1) the radiation heating of both the CFRTP sheet and the mold cavity surface using a far-infrared radiation heater, (2) the compression molding of the CFRTP sheet, and (3) the injection molding of the melt. The effects of the heating conditions of the mold and the injection molding process conditions on the appearance characteristics of the molded products are clarified using this mold and a far-infrared radiation heater. |
| first_indexed | 2024-03-09T16:30:33Z |
| format | Article |
| id | doaj.art-8ab90690772644b087cfa2f487f7bc9b |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-09T16:30:33Z |
| publishDate | 2023-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-8ab90690772644b087cfa2f487f7bc9b2023-11-24T15:02:37ZengMDPI AGPolymers2073-43602023-11-011522443710.3390/polym15224437Influence of Processing Conditions on the Generation of Surface Defects in a Heat-and-Cool Hybrid Injection Molding Technique for Carbon Fiber-Reinforced Thermoplastic Sheets and Development of a Suitable Mold Heated by Far-Infrared RadiationYasuhiko Murata0Ryunosuke Machiya1Takuma Komori2Department of Mechanical Engineering, Faculty of Fundamental Engineering, Nippon Institute of Technology, 4-1 Gakuendai, Miyashiro-machi, Minamisaitama-gun, Saitama 345-8501, JapanMechanical Systems Engineering Major, Graduate School Nippon Institute of Technology, 4-1 Gakuendai, Miyashiro-machi, Minamisaitama-gun, Saitama 345-8501, JapanMechanical Systems Engineering Major, Graduate School Nippon Institute of Technology, 4-1 Gakuendai, Miyashiro-machi, Minamisaitama-gun, Saitama 345-8501, JapanRecently, hybrid injection molding—a type of overmolding technology in which a short carbon fiber-reinforced thermoplastic is injection molded over a compression-molded carbon fiber-reinforced thermoplastic (CFRTP) sheet—has been introduced. A heat-and-cool hybrid injection molding technique has also been introduced for practical use. The technique yields high-quality molded products. This is achieved through the heating of the mold cavity surface to a temperature higher than the melting point of the base polymer impregnated into the carbon fiber fabric. However, few experimental analyses of the molding phenomena in heat-and-cool hybrid injection molding have been reported. In particular, the effect of the processing conditions on the transfer of the mold cavity surface shape to the CFRTP sheet has not been clarified in detail. Therefore, it has been impossible to take extensive measures when defects are generated in molded products. In this study, a mold is designed and fabricated for use with far-infrared radiation heating, a variotherm technology that is suitable for the experimental analysis of the heat-and-cool hybrid injection molding phenomenon. In particular, a mold is designed and fabricated to continuously perform the following three processes using only an injection molding machine: (1) the radiation heating of both the CFRTP sheet and the mold cavity surface using a far-infrared radiation heater, (2) the compression molding of the CFRTP sheet, and (3) the injection molding of the melt. The effects of the heating conditions of the mold and the injection molding process conditions on the appearance characteristics of the molded products are clarified using this mold and a far-infrared radiation heater.https://www.mdpi.com/2073-4360/15/22/4437carbon fiber-reinforced thermoplastic sheetheat-and-cool hybrid injection moldingfar-radiation heatersurface defecttemperature measurement |
| spellingShingle | Yasuhiko Murata Ryunosuke Machiya Takuma Komori Influence of Processing Conditions on the Generation of Surface Defects in a Heat-and-Cool Hybrid Injection Molding Technique for Carbon Fiber-Reinforced Thermoplastic Sheets and Development of a Suitable Mold Heated by Far-Infrared Radiation Polymers carbon fiber-reinforced thermoplastic sheet heat-and-cool hybrid injection molding far-radiation heater surface defect temperature measurement |
| title | Influence of Processing Conditions on the Generation of Surface Defects in a Heat-and-Cool Hybrid Injection Molding Technique for Carbon Fiber-Reinforced Thermoplastic Sheets and Development of a Suitable Mold Heated by Far-Infrared Radiation |
| title_full | Influence of Processing Conditions on the Generation of Surface Defects in a Heat-and-Cool Hybrid Injection Molding Technique for Carbon Fiber-Reinforced Thermoplastic Sheets and Development of a Suitable Mold Heated by Far-Infrared Radiation |
| title_fullStr | Influence of Processing Conditions on the Generation of Surface Defects in a Heat-and-Cool Hybrid Injection Molding Technique for Carbon Fiber-Reinforced Thermoplastic Sheets and Development of a Suitable Mold Heated by Far-Infrared Radiation |
| title_full_unstemmed | Influence of Processing Conditions on the Generation of Surface Defects in a Heat-and-Cool Hybrid Injection Molding Technique for Carbon Fiber-Reinforced Thermoplastic Sheets and Development of a Suitable Mold Heated by Far-Infrared Radiation |
| title_short | Influence of Processing Conditions on the Generation of Surface Defects in a Heat-and-Cool Hybrid Injection Molding Technique for Carbon Fiber-Reinforced Thermoplastic Sheets and Development of a Suitable Mold Heated by Far-Infrared Radiation |
| title_sort | influence of processing conditions on the generation of surface defects in a heat and cool hybrid injection molding technique for carbon fiber reinforced thermoplastic sheets and development of a suitable mold heated by far infrared radiation |
| topic | carbon fiber-reinforced thermoplastic sheet heat-and-cool hybrid injection molding far-radiation heater surface defect temperature measurement |
| url | https://www.mdpi.com/2073-4360/15/22/4437 |
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