2012 Moldex3D R11 European Webinar Series

Co-injection Process Technical Challenges and Solutions

Shih-Po Sun, Ph.D.

Current position:
CoreTech System Technical Research Division

Education:
PhD in Polymer Science from the University of Connecticut

Specialization:
Polymer rheology, processing, and properties, polymer composite, biomedical materials, degradable polymers, and plastics applications in industrial design
Dr. Sun has researched parenteral drug packaging in Eli Lilly and Company. He has also worked with Teleflex Medical to develop a fully absorbable bone graft composite. He is now a senior research engineer supporting the development of advanced injection molding CAE software and also in charge of material testing and measurement in Coretech System company.
2

Contents
> Part 1:
Introduction to co-injection molding Product common defects and solutions Product development through CAE

> Part 2:
Case study 1: Earphone hook Meeting product spec how to resolve unwanted warpage Case study 2: Car door panel Prioritize gate location for ideal filling pattern

Multi-material injection

Also called multi-component injection molding (MCM)

Processes of combining different material qualities and properties in one component.

Co-injection PP EVOH

In-mold assembly

PC

TPV

PP

Multi-material injection family

Multi-material processes

Multi-component

Multi-shot

Over-molding

Rotating tool Bi-injection Insert

Core back Co-injection (Sandwich) Transfer Lost core

Skin / core combinations

Handle, lever : Soft feel skin / hard core

Computer housing: Unfilled skin / core with conductive filler

Garden furniture: Virgin skin / recycled core

Yogurt pot: Pigmented skin / uncolored core

6

Stages

Step 1 Empty cavity 1st shot (skin): blue 2nd shot (core): yellow

Step 2 Skin injection

Step 3 Core injection

Step 4 Second skin injection for 1-2-1 structure

Todays objective - aesthetics

Structural product: co-injection is preferred to conventional structural foam or fiber reinforced plastics because of its superior surface finish. A solid skin combined with a structural foam core provides the advantages such as low molded-in stress, sink-free parts without the skin surface defects Quality surface is obtained in fiber reinforced plastics since the fiber-loaded material is restricted in the core of the part.

Todays objective - property combination

Combined properties: one can achieve a combination of properties not available in a single resin by combining different materials. For instance: An elastomeric skin over a rigid core will provide a structure with a soft touch. A brittle material can be encased by a material of high impact resistance or high ductility.

Sustainability

10

Benefits of using co-injection molding

> Recycled core reduces costs > Recycled core reuses waste > Engineering core structure, e.g. fiber foaming, enhances product strength or performance > Virgin skin provides quality aesthetic finish for recycled or engineering core > Elastomer skin improves surface touch > No increase on cycle times comparing to sequential or multi-component molding
11

Important processing considerations

> Strength Material adhesion > Skin / core distribution Flow characteristics > Specification Shrinkage / Warpage > Performance Material selection

Related processing conditions: Material properties, injection rate, skin-core transition ratio, skin/core temperature and packing pressure

12

Machine design - nozzle

13

Machine design hot runner

14

Machine design multiple gate

15

Multi-Material Molding Process Comparisons

Process Interface Controllability # of Nozzles # of Materials Mold Complexity Part Complexity Use of Preforms Co-Injection Poor 1 2 Low Simple No Bi-Injection Poor n 2 Low Very simple No Insert Molding Good 1 2 Low Medium Yes Over Molding Good n 2 Medium High No Multi-Shot Good n 2 High Very high No

interface depends on the laminar flow of materials interface is controlled by the mold geometry n the number of separate materials being used

Source: http://www.isr.umd.edu
16

How to turn single shot machine into a co-injection one?

Source: Krauss Maffei

17

Co-injection machine design - Melt

Milacron

18

Co-injection machine design Mold

Meiki

Master Mold Plate

US patent 6196822

19

Co-injection machine design - Screw

Spirex Twinshot

20

Material compatibility

Source: Engel
21

Material Properties
& Viscosity f ( , T, P, )
Volume f (T, P)

Heat conductivity f (T)

Heat capacity f (T)

22

Equations to describe melt flow

Mass balance + ( u ) = 0
t

Density,

Momentum balance Du = p + g Dt Energy balance

Cp
T + u T = k T : & t

Relationship between and u or viscosity, Heat capacity, Cp Thermal conductivity,

CAE procedure

Thermoset conversion balance

& X + j+ R = 0
Conversion rate,

Flow behavior

Temperature-pressure dependent volume, Modulus, G

V(T, P)

Cooling, warpage analysis

23

Important questions

How does my change of design affect the skin/core distribution?

What is my flow orientation for the core layer? If the core is fiber filled.

Where is the area with high stress and temperature?

How does the core layer affect overall warpage?

24

Skin / core evolution

25

Viscosity limitations of 2 materials

> Two materials can only be processed successfully by coinjection molding if their processing properties match. Previous studies have suggested that the core/skin viscosity ratio should be between 0.5 and 5. > Lower viscosity ratios would lead to breakthrough of core material. > Higher viscosity ratios would lead to poor mold filling, finger like defects and a variable core thickness through the part.
Gomes, 2011, Polym Eng. Sci.

26

Effect of viscosity ratio

viscous

Yottha Srithep, 2008

27

Effect of viscosity ratio

Skin-core ratio (1st shot volume / total volume) 80% Higher 70% 60%

2nd shot viscosity compared to 1st shot

Lower

B Material: PC
28

Injection rate effect

Yottha Srithep, 2008

29

Injection rate effect

Skin injection speed constant Core injection speed

30

Material break through

Source: C-Mold
31

Core filling ratio

Vcore/Vtotal

32

Material break through prediction

Two opposing forces: viscosity vs. filling ratio Less viscous core requires higher skin filling ratio to prevent break through.

33

Controlled break out technique

Lattoflex, Winx300 IF 99 design award

34

Break through simulation

35

Cornering effect

> Uneven distribution, uneven thickness

Source: Gas-assist injection molding: principles and applications

Flow around corners must be considered in design phase to prevent thin inside corners. Use a generous radius.
36

Design considerations

Material selection Mold design Processing condition Part design

Flow behavior

Quality product
Material distribution vs. Design criteria?

37

Questions

If I want to Which design change is possible?

38

Benefit of CAE
CAE is a must in predicting the spatial distribution of core and skin. General knowledge is difficult to predict the simultaneous flow of two materials. Knowing the melt front evolution of both shots, CAE can:
Evaluate the flow front pattern to aid in part design and gate placement Predict the extent of penetration of the core material and the skin breakthrough point Determine injection pressure and clamping force for proper molding machine selection Determine the best switch point from skin injection to core injection

39

Benefits of Moldex3D
Moldex3D can help users in all aspects of co-injection molding process: > For mold design, locate the optimum gate locations > For cost reduction, evaluate the maximum core ratio without causing break through. > For structural analysis, provide skin thickness distribution. > For quality control, pinpoint potential locations with high temperature and stress. > For spec requirement, precisely estimate shrinkage and warpage concerning the interaction between skin and core material.
40

Case Study 1: Earphone hook

> The hook connects to the phone and mic assembly. > The hook design has a flexible skin to provide better feel of touch in contact with the ear. > The hook should have enough stiffness to withstand deformation. > The hook dimension should meet specification.

41

Original sequential design

PP

TPE

42

Using co-injection process

Benefit: > The co-injection process provides ideal material combination of soft skin / hard core to meet design criteria. Concern: > Part and process design to reach desired mechanical strength > Warpage due to imbalanced core distribution

43

Melt front evolution

44

Skin ratio
90% 80%

70%

50%

Break through occurred!

45

Skin ratio

46

Cornering effect

Core travels toward inside of the corner

47

Shrinkage, X-axis direction

10

48

48

Gate location design

49

70% skin filling ratio

50

Controlled break through

40% skin filling ratio

0.07 s Break through occurred

51

52

Skin ratio

53

Shrinkage, X-axis direction

10

54

Moldex3D FEA workflow

Flow analysis

+
Material parameters

Element properties

Structural simulation software

55

Structural analysis result

B.C. Fixed location around the joint

Load 500g of force applied at the end

56

Deformation results

57

Case study 2: door panel

> The size of the door panel requires multiple gate mold design. > The core amount should be maximized without surfacing.

58

Using co-injection process

Benefit: > Co-injection integrates rigid and flexible components into a single molded structure with a single step. > The core should be completely contained within the flexible material. Concern: > Number and location of the gates to ensure balanced melt flow and material distribution > Warpage due to imbalanced core distribution

59

Information
> Dimension
> Dimension710476 mm > Thickness : 7 mm > Volume 1660 c.c.
Hot Runner 12.0 mm 8.0

> Material
> Skin : TPO > Core : PP

> Processing condition

> Time (total): 5 s > Melt temperature: 260 C > Mold temperature: 40 C
Gate Type : circular Diameter8 mm

60

Single skin material filling

61

Skin /core material filling

62

Number of gates

5 gates, 60% skin ratio

6 gates, 60% skin ratio

63

Increasing skin ratio

6 gates, 70% skin ratio

6 gates, 80% skin ratio

64

Gate location modification

65

66

Gate contribution

67

Skin ratio

68

Clamping force

Skin in contact with the wall

69

Volumetric shrinkage

70

Warpage, Y-direction

71

Conclusions

> Co-injection process brings design versatility to newly designed or existing products. While the transition to coinjection process from already own equipment is not difficult, optimizing part design and processing conditions to achieve desired material distribution poses challenges. > CAE flow analysis is an indispensible tool providing complete solution for managers, designers, and engineers to fully control the outcome of their fiber reinforced plastic product. > Modules in Moldex3D work seamlessly together providing invaluable information throughout the entire design, manufacturing, and usage phases.

72

If you have questions, please type into the chat box.

73

Contact Information

Dr. Sun
tobersun@moldex3d.com

Dannick
dannickteng@moldex3d.com

Vincent
vincenthung@moldex3d.com

74

Next Webinar Topic

Latest Development in Long / Short Fiber Reinforced Plastics Applications, Processing Techniques and Simulation Technology

Goals
Lean how to estimate fiber orientations to gain strategic benefits by adopting CAE incorporated design. Have an overview on the design work flow from part geometry all the way to dimension accuracy and mechanical properties. Speed up your fiber product development with a clearer view on most important design considerations and processing controls.

Time
9:00AM UTC -13 January,2012
75