Research On In-mold Decoration Molding Process In Automotive Interior

With the development of automotive industry, the interior of automobile isbecoming the new target of vehicle designing or the selling point of new car. Attractive,durable automotive interior materials will give consumers strong visual impact andunprecedented comfortable experience. Therefore, the research on interior manufacturetechnology aim at making it more beautiful, more durable and more environmentallyfriendly. In-mold decoration is one of new surface decorarion technologies whichrepresents the research trend. This study gave the classidied introduction of IMDprocess theoryies and characteristics. Designed the IMD process for an door handle partof a car. Built finite model and did optimization research for shooting effects withMoldflow software.This study separated IMD technology into three parts IML, IMR and INS and gavethe breif introduction for each one. Confirmed IML (in-mold label) as the main point ofthis study. Built mathematical model for fluid filling and flow performance wheninjection moulding. Some reasonable simplification and assumption were accomplishedas well.A3D model and a optimization modle with Fusion mesh of a door handle werebuilt in this study and one more mesh was added on the surface of model to simulate thedecoration film. ABS+PC material were chosen to be injection material, meanwhile twotypes of injection systems, cooling systems and other technological parameter were setup.The simulation reesults indicated that one of the two types of injection systems gotbetter molding effects and would be more suitable for IMD technology.A new experiment was arranged to comparing different molding effects of fourmaterials: PP, PMMA, PET and ABS, regarding warping quantity and shrink rate asevaluation index. The results indicated PET and ABS would be more suitable.A design of experiments study was also conducted using in-rnold filrn tounderstand how rnelt ternperature, mold ternperature, cavity pressure and dwell timecontributed to warping quantity and shrink rate. The result pointed out that the mostsignificant factors for warping quantity and shrink rate, and determined the bestmolding process.The results of this study would provide references for IMD automotive interiormanufacture and molding process parameters designing.