IMD/IMF hot-pressing molding process in IMD injection molding insert technology is blowing towards the whirlwinds of plastic surface technology industry in China, is the most traditional plastic surface treatment technology challenges, such as coating industry is also a severe test of foreign processing of small and medium-sized enterprises oriented, how to face, is on the sidelines waiting; Or drift?
We hope you will choose according to oneself circumstance to determine if your, IMD industry is a high cost, abundant profits industry, how to succeed in this industry, depends on whether you in costs under control? How to select raw materials? How to improve the skills? How to reduce the process defective rate? How to get reasonable price, and so on.
On IML/IMD/IMF defective rate of the main control in printing and injection parts, the choice of film forming equipment also determines the stability of film forming is an important factor of yield, in the current film molding equipment on the market basically has hot-pressing machine, suction machine, empty and high pressure gas forming machine, its price difference is very big, the general hot press about thousands of yuan, the price of vacuum machine depends on its function size, tens of thousands of yuan to hundreds of thousands of yuan, high pressure gas forming machine is IMD/IMF/on IML equipment in recent years, first of all, from the United States, Germany's development in Taiwan, the United States of the equipment in more than 200 yuan, Germany equipment in more than 300 yuan, Taiwan's equipment at around 1 million, demand manufacturer according to different products, and use different material and printing graphic to consider product drawing and positioning two aspects to consider equipment selection.
IMD yield also includes the control of the environment, we ask for the whole process of IMD is conducted in a clean room, in the part of printing not to speak, in the high pressure molding and injection part and so we ask, because the sheet heating, because particles easily with sheet together IMD has two kinds big, namely on IML/IMD, customarily referred to as the IMD.
IMD (in mould - decoration)
There are two categories:
One is the IMD, it refers to is put a screen printing patterned film in plastic moulds for plastic injection. The flim can be roughly divided into three layer, base material (generally for pet) - ink (ink) - wear resistant material (as a special kind of glue).
When after the completion of the injection molding, film and plastic, wear-resistant material on the outside.
In the mobile phone screen in this process, the more plastic material for PC, pmma, PBT, etc., it mainly has the effect of wear resistance and scratch resistance.
For PC thick, only can use silk screen printing, so the effect is rough.
There is a call on IML (in - mould - label) technology, and IMD is roughly same, just after the injection flim pull like stamping of strip, just will transfer to the plastic printing design, also known as a mould heat transfer.
Flim is pet material, like a movie film, also called chain (foil); Pet sheet, offset printing are available, and is very delicate, especially electroplating and transparent, delicate metal and surface texture is very good.
Wait cutting aniseed - > heat setting - > cut small material - > punch positioning - > printing - > - > check - > curing eye stick protective film - > - > - > cutting molding (bridging brand moulding machine) -- - > > plastic injection online inspection - > stick protective film - > gate repaired - > semi-finished products inspection - > back glue - > finished product - > stick protective film - > finished product packaging
The molding design mold shrinkage problem Generally 0.5% of abs, pmma, such as do the IMD mold, because the product surface to cover a layer of pet film, obviously the heat shrinkage rate is different.
According to my experience, IMD mold die bei the shrink of the products than ordinary die, take 0.3% more appropriate. Because, when we do the injection plastic substrate by sheet package, the plastic shrinkage have played an important role in blocking.
The problems of this plate sheet is key to the success or failure of the IMD mold; Is also the most complicated problem. Several analysis the following points:
A, the material, printing ink
General sheet material for the pet and PC and pmma sheet. But pet molding and processing are relatively good. Surface gloss, abrasion resistance and meet customer requirements, so widely used material. 0.125 mm thick pet sheet for one of the most hot plate.
Ink for printing materials for wear resistant, high temperature resistant, blending, silk screen operation is convenient.
B, prefabricated sheet (cutting, thermoforming)
The general technological process is:
Sheet option - > printing tools: film, silk pad printing machine; the point: ink selection, sheet)
-- > stick protective film
- > appearance blanking (tools: die cutter; the point: sheet)
-- > stick protective film
-- > heat styling (tools: heat setting machine; point: temperature control)
-- > stick protective film
Please be reminded that is less than the not process, please protect and dustproof effect; Protective film with PE film in general.
Heat setting process diagram:
In heat setting link, temperature control is very important, grasp is not good, easy to make the sheet deformation, scrap rate is high.
Upper and lower mold heat setting machine, there is the heating plate, maintain a constant temperature during the work. Mobile after heating plate into the sheet, moved to the top sheet sheet for preheating, make its become soft, can only be clamping heat setting processing!
C, with the sheet and the mold cavity
Sheet size than the final parts size a little bit. - the most important principle!
In general, it is suggested that: the size of the sheet than unilateral small parts size 0.02 to 0.03 mm
So sheet in cavity is easy, to completely stretched. If there are any fold, beer out of the finished product will be bad.
3. Sheet forming die design points
A, use the product figure, in pro/e (or other 3 d software) according to the thickness of the sheet, the product surface inward offset, get the 3 d map sheet. - the most troublesome work!
B, according to the sheet of the 3 d map, it unfolds, cutting die for blanking sheet, film, etc.
C, according to the sheet 3 d drawing die
D and manufacture of moulds