Development of a rapid heat cycle injection molding system using infrared radiation and convection heating and influence on morphology and mechanical properties

Conventional injection molding is widely used to produce plastic parts, mainly in the automotive industry, due to the high production ratios and quality of injection parts. Low mold temperatures are usually employed to decrease cycle molding time and final process costs; however, resulting surface defects include weld lines, sink marks, and warpage. Therefore, plastic parts are often subjected to secondary processes to reduce the surface defects. A dynamic mold heating and cooling control technology, rapid heat cycle molding (RHCM), was employed to optimize the injection molding process. The present study combined convection heating (pressurized water flow) and external infrared heating systems to investigate the effect of dynamic temperature control on the injection molding process. The infrared heating system was custom built to allow studying under controlled conditions the influence of several process parameters on the resulting morphology and mechanical properties. Results show significant gains from using the RHCM technology to optimize the conventional process, namely, at 100 degrees C no frozen layer is formed while simultaneously increasing the Young's modulus. Industrial companies struggling with defects resulting from the thermal changes during injection molding can thus consider RHCM as a mitigation strategy and use these results as a guide for tool design and implementation of the technique.