• Elastomers and Composites
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• v.47 no.4
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• pp.341-346
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• 2012

Injection molding is one of the widely used polymer processing operations. It is being used for not only conventional injection molding but gas injection molding, water injection molding, and injection compression molding. Injection compression molding involves injection and compression operation, and it gives uniform physical property and high dimensional quality of product. In this study, injection compression characteristics for various product shapes have been investigated by computer simulation. Product containing side wall showed not much effective in injection compression molding since wall thickness direction was perpendicular to the compression direction. Uniform and low shrinkage was observed in injection compression molding comparing conventional injection molding. Subsequently injection compression molding can be used for molding precise product. Optimal injection compression molding condition was obtained using design of experiment for plastic lens and the results were compared with conventional injection molding.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.1
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• pp.39-46
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• 2013

This study aims to develop a plastic aspheric lens for a 13-megapixel mobile phone camera by injection-compression molding. A mold for injection-compression molding experiments was fabricated with a movable upper plate and four springs. During cavity filling for an aspheric lens with a thickness ratio of 2, a weldline was formed under conventional injection molding, whereas no weldline was formed under injection-compression molding with a compression stroke of 0.3 mm. The flow patterns were in good agreement with the simulation results. The birefringence decreased as the compression stroke increased, and the birefringence produced by injection-compression molding was very low and more uniform compared with that produced by injection molding. In addition, the bulk birefringence of an assembly composed of four plastic lenses was significantly affected by the orientation of the lenses to be mounted.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.38 no.7
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• pp.771-777
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• 2014

Injection-compression molding was used for film insert molding of an automotive door grip using films with three-dimensional embossed patterns. A vacuum mold was fabricated for vacuum-assisted thermoforming of the film, and an injection-compression mold was developed for film insert molding. Three pressure transducers were installed inside the mold cavity to measure cavity pressures. Injection-compression molding experiments under various compression strokes and toggle speeds were performed to investigate their effects on the cavity pressure and heights of the embossed patterns. The compression stroke of 0.9mm and low toggle speed resulted in a higher degree of conservation of embossed patterns. Additionally, the processing conditions for the maximum heights of embossed patterns were almost similar to those for minimum integral value of cavity pressures. The injection-compression molding process presents the opportunity to impart a soft-touch feeling of plastic parts printed with embossed patterns.

• Polymer(Korea)
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• v.38 no.2
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• pp.144-149
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• 2014

Large residual stresses are remained in the conventional injection molded products because of the high cavity pressure in packing phase during injection molding process. Conventional injection molding (CIM) invokes distribution of cavity pressure and it has a limitation to obtain product with uniform physical property. Multi-cavity conventional injection molding contains quality deviation among the cavities since flow imbalance occurs during filling phase. Injection compression molding (ICM) is adopted to overcome these limitations of CIM. In this study, molding characteristics of CIM and ICM have been investigated using multi-cavity injection mold. Researches were performed by both experiment and computer simulation through observations of birefringence for transparent resins, polycarbonate and polystyrene in CIM and ICM. As a result, low and uniform birefringence and mold shrinkage were showed in the specimens by ICM that could give a uniform cavity pressure. Deviation of physical property among the specimens in multi-cavity mold shown in CIM was significantly reduced in the specimens by ICM. Through this study it was concluded that the ICM in multi-cavity molding was valid for molding products with uniform property in an individual cavity and also reduced property deviation among the cavities.

• Polymer(Korea)
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• v.38 no.2
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• pp.193-198
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• 2014

Lens and DVD require high quality of optical property. Conventional injection molded products contain high residual stress and this invokes birefringence since high cavity pressure and high temperature variation are involved in a molding process. Thus these products are often molded by injection compression molding in order to minimize the residual stress through reducing cavity pressure and uniform cavity pressure. In this study, molding parameters affecting molding quality such as property uniformity in injection compression molding were investigated through experiment. Molding quality deviations among the cavities in multi-cavity mold were also studied. Transparent resins, PC and PS were used in this study. Compression gap, compression speed, compression force, and compression delay time for processing variables in injection compression molding were applied in experiment. Compression force, compression delay time, and compression gap significantly affected the optical property of product. The degree of influence of process variable on the product quality was different in different resins. This implies that the optimal operational conditions in injection compression molding existed for each resin according to flow property.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.227-232
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• 1995

사출성형(Injection Molding)은 생산성이 좋으며 마무리가공을 거의 필요로 하지 않는 정형 형태( net shape)로 제조가 가능하고 복잡한 형상을 만들 수 있어 고분자 재료의 대부분이 사출성형법에 의해 성형 되고 있다. 최근들어 가볍고 강도가 매우 높은 고분자재료의 개발로 전기전자 제품은 물론 자동차, 항공기 등의 생산에 이르기까지 사출성형의 중요성은 더욱 가속화되고 있다. 본 연구에서는 복잡한 형상과 여러 형상의 캐비티를 갖는 경우에는 동시에 충진이 완료되기가 어렵다. 따라서, 다른 캐비티가 충진되고 있는 동안에 먼저 충진이 된 캐비티에서 고분자 수지는 압축을 받고있기 때문에 사출성형품의 치수정밀도를 향상시키기 위한 좀더 정확한 압력과 온도분포를 예측하기 위하여 기존 의 충진과정과 충진후과정(보압, 냉각과정)을 분리하여 해석 하는 것이 아니라 충진과정과 충진후과정을 동시에 해석할 수 있는 프로그램(program)을 만들었다.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.218-224
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• 1999

It is necessary to improve mechanical and optical properties in the optical disk substrates as the information storage devices with high storage density using short wavelength laser are being developed. Injection compression molding is regarded as the most suitable process to manufacture optical disk substrates with high is regarded as the most suitable process to manufacture optical disk substrates with high dimensional accuracy low residual stresses and superb optical properties In the present study polycarbonate optical disk substrates were fabricated by injection compression molding and the birefringence regarded as one of the most important optical properties for optical disk is measured. The effects of various processing conditions upon the development of birefringence distribution were examined experimentally. It was found that the value of the birefringence distribution were very sensitive to the mold wall temperature history and the variance of the birefringence distribution in the radial direction was affected by the level of the packing and the compression pressure.

• Journal of Power System Engineering
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• v.9 no.4
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• pp.83-89
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• 2005

Molding shrinkage is one of the problems to be solved in conventional injection molding. Despite many trying-out has been to solve it, intrinsic cause of shrinkage such as orientation and thermal exchange between melt and mold has not been solved yet. For reducing shrinkage and residual stress on molding, injection compression molding process was invented. In this study, experiments about effects of injection compression molding's parameters on shrinkage of PMMA molding were conducted and compared with conventional injection molding's shrinkage. Before the injection compression molding experiment, molding shrinkage rate was predicted by analyzing pvT diagram and was compared with the results of experiment. The shrinkage rate of injection compression molding was lower than convention injection molding's one which was different from the predicted shrinkage. The reason was observed that the experimental mold was not a proper type for injection compression, flowing backward of melt into nozzle and unreasonable mechanism of injection molding machine.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.445-448
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• 2005

Recently, injection molding process became more popular than ever to produce large quantities of high precision products or optical products. Injection molding products can cause sensorial problems because of high birefringence or deformation from the residual stresses in the optical media. In the present study, we have focussed on the effect of holding and compression pressures on the optical anisotropy remaining in the MOD by examining the gapwise distribution of birefringence and extinction angle The effect of holding pressure was found to form the inner two birefringence peaks. But the effect of compression pressure on the birefringence distribution was found to make the uniform distribution near the center in the gap-wise direction. Finally, the value of the birefringence near the wall decreased as the mold temperature increased.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.11 no.4
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• pp.1361-1366
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• 2010

This research aims to develop polymer composites which can be used for PEMFC separators by injection molding process. Considering the moldability and stiffness, we used PPS(Poly(phenylene sulfide)) and PP(Polypropylene) as base resin. In order to improve electrical conductivity and physical properties, we chose glass fiber, carbon fiber, carbon black, and both expanded graphite and synthetic graphite. The 3 type composites are prepared for injection molding of PEMFC separators. and CAE(Computer Aided Engineering) analysis was conducted to optimize injection processing parameters(injection pressure, heat time, mold temperature etc.). We did successfully fabricate the separators by injection molding, and measure the electrical conductivity of the samples by using four point probe device. Conclusively, PP/SG/CB composite showed better both electrical conductivity and moldability than the others.