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Conference Proceedings
MECHANICAL PROPERTIES OF HEAT SEALED RECYCLED POLY(ETHYLENE TEREPHTHALATE) SHRINK FILM
Rei-ichi Konishi, Kazushi Yamada, Yasuo Hashimoto, Yew Wei Leong, Tetsuya Tsujii, Hiroyuki Hamada, May 2010
In recent years, the development of recycling methods for waste PET bottles has generated much interest due to environmental and waste management concerns. Therefore, in this study, recycled PET (RPET) was considered instead of PS or PVC to prepare shrink films for labeling purposes. However, the labels would still have to be removed from the bottles prior to recycling due to color incompatibility. For this reason, the tear properties of the RPET labels, especially at the heat sealed regions, are elucidated and correlated to film crystallinity and molecular orientation.
MECHANICAL PROPERTIES OF HEAT SEALED RECYCLED POLY(ETHYLENE TEREPHTHALATE) SHRINK FILM
Rei-ichi Konishi , Kazushi Yamada , Yasuo Hashimoto , Yew Wei Leong, May 2010
In recent years, the development of recycling methods for waste PET bottles has generated much interest due to environmental and waste management concerns. Therefore, in this study, recycled PET (RPET) was considered instead of PS or PVC to prepare shrink films for labeling purposes. However, the labels would still have to be removed from the bottles prior to recycling due to color incompatibility. For this reason, the tear properties of the RPET labels, especially at the heat sealed regions, are elucidated and correlated to film crystallinity and molecular orientation.
CHARACTERIZATION OF WPC PRODUCED USING COMPRESSION MOLDING WITH DIRECTIONAL FIBER ALIGNMENT
M. R. Islam, H. Semeralul, G.M. Rizvi, E. Haghverdian, May 2010
Wood Plastic Composites (WPC) require improvements in properties such as strength, which will help WPC find applications in areas where it is now deemed unsuitable. Compression molding provides a quick method for preparing test specimen. During extrusion a substantial amount of wood fibers get aligned in the direction of flow, whereas, in compression molding these are generally randomly oriented in two dimensions. A properly designed mold ensures greater uni-directional alignment of fibers so that test specimens have greater similarity of fiber orientation with extruded profiles. In this paper, a compression molding system, designed to provide greater one dimension extensional flow is discussed.
INTEGRATED ANALYSIS OF CAD AND CAE FOR HOT-RUNNER DESIGN
Wen-Ren Jong, Ping-Huei Lee, Yu-Cheng Chang, Tai-Chih Li, Yu-Hung Ting, Jerry Hsu, May 2010
To maintain the constant temperature for the plastic inside the hot-runner manifold is an important quality control in mass-production injection-molding process with hot-runner design. Without the constant and uniform temperature distribution, the molded parts wonƒ??t have good yield percentage. As such, this work takes CAD model and the temperature of heater to simulate the temperature distribution of hot-runner manifold. The results show very good agreement with the experimental verification and can be utilized to improve the heater design and efficiency, as such the temperature distribution of manifold can be further optimized.
INTEGRATED ANALYSIS OF CAD AND CAE FOR HOT-RUNNER DESIGN
Wen-Ren Jong , Ping-Huei Lee , Yu-Cheng Chang , Tai-Chih Li , Yu-Hung Ting , Jerry Hsu, May 2010
To maintain the constant temperature for the plastic inside the hot-runner manifold is an important quality control in mass-production injection-molding process with hot-runner design. Without the constant and uniform temperature distribution, the molded parts won’t have good yield percentage. As such, this work takes CAD model and the temperature of heater to simulate the temperature distribution of hot-runner manifold. The results show very good agreement with the experimental verification and can be utilized to improve the heater design and efficiency, as such the temperature distribution of manifold can be further optimized.
EFFICIENCY EVALUATION OF GAS-ASSISTED HEATING AND ITS APPLICATION TO DYNAMIC MOLD TEMPERATURE CONTROL TO IMPROVE MICRO-FEATURED MOLDING
Shia-Chung Chen , Yaw-Jen Chang , Sung-Wei Huang , Jen-An Chang , Je-Wei Yang, May 2010
In the study a gas-assisted heating system was established and its efficiency evaluated. Relevant parameters including the variable geometry for gas entrance (Circular and Divergent channel) gas temperature and gas flow rate as well as the mold surface coating of ZrO2 were varied for heating efficiency consideration. The results show that the maximum heating rate and temperature reached 33oC/s and 245.3oC when air temperature was 500oC at a flow rate of 400 L/min. It was also found that the divergent entrance channel obtains better temperature uniformity. Finally a case study of molding biochips with a micro channel showed replication accuracy increases of up to 22%.
EFFICIENCY EVALUATION OF GAS-ASSISTED HEATING AND ITS APPLICATION TO DYNAMIC MOLD TEMPERATURE CONTROL TO IMPROVE MICRO-FEATURED MOLDING
Shia-Chung Chen , Yaw-Jen Chang , Sung-Wei Huang , Jen-An Chang , Je-Wei Yang, May 2010
In the study, a gas-assisted heating system was established and its efficiency evaluated. Relevant parameters, including the variable geometry for gas entrance (Circular and Divergent channel), gas temperature, and gas flow rate, as well as the mold surface coating of ZrO2, were varied for heating efficiency consideration. The results show that the maximum heating rate and temperature reached 33oC/s and 245.3oC when air temperature was 500oC at a flow rate of 400 L/min. It was also found that the divergent entrance channel obtains better temperature uniformity. Finally, a case study of molding biochips with a micro channel showed replication accuracy increases of up to 22%.
EFFECT OF PROCESSING CONDITIONS ON MECHANICAL PROPERTIES OF ULTRA HIGH SPEED INJECTION MOLDED ABS PARTS
Hsin-Shu Peng , Shia-Chung Chen , Hsien-Hsun Tseng , Peming Hsu , Yu-Tseng Lin, May 2010
It is known that the ultra high speed injection molding is a proper solution for molding thin-wall parts.This study investigates the effect of processing conditions including melt temperature, mold temperature, injection speed on mechanical strength of molded ABS parts. Both single gate and double gates tensile test specimens were molded with and without weldlines. It was found that higher melt temperature and mold temperature as well as faster injection speed would increase tensile strength.Faster injection speed will also influence part mechanical properties, particularly in Young's modulus will increase of 15%, due to flow-induced molecular orientation along melt flow direction.
REAL-TIME CHARACTERIZATION OF POLYPROPYLENE NANOCOMPOSITES IN A COROTATING TWIN SCREW EXTRUDER
Shia-Chung Chen, Yi-Chang Lin, Hsien-Hsun Tseng, May 2010
Using layered silicates in polymer processing developed rapidly over the last decade. Depending on the particle structure in the polymer a significantly higher level of reinforcement can be achieved. Characterization of nanocomposites is usually done with optical, mechanical and light scattering methods, which are offline and require very time consuming sample preparation and tests. In contrast, implementing in-line near infrared spectroscopy in a twin screw compounder enables real-time material characterization during compounding and provides a powerful instrument for quality control and optimization of the compounding process in terms of increased and constant quality.
VERIFICATION AND SIMULATION OF MELT FLOW BEHAVIOR IN ULTRA HIGH-SPEED INJECTION MOLDING
Shia-Chung Chen , Yi-Chang Lin , Hsien-Hsun Tseng, May 2010
CAE technology can anticipate the injection conditions before real injection molding begins.However, the parameter settings of the software require modification for ultra high-speed injection molding. In this study, we tested the flow length and used Moldflow Plastic Insight (MPI) to demonstrate the experiment using injection speeds of 100 mm/s to 1100 mm/s. The model is a spiral shape with a thickness of 0.4 mm and a width of 6 mm. We found that HTC value of software affects seriously flow length above injection speed of 700 mm/s, because this value relates to the heat transfer.The trend of flow length in the experiment is the same as in the simulation, but at injection speeds above 700 mm/s, the margin of error becomes large, about 21.7% for 900 mm/s, and 19.3% for 1100 mm/s. Clearly, the parameter settings for ultra high-speed injection molding require special adjustment.
A STUDY ON THE FLASH GENERATION OF LARGE SURFACE AREA THIN-WALLED CO-INJECTION MOLDING
Pao-Lin Su, Shia-Chung Chen, Hsin-Shu Peng, Hsien-Hsun Tseng, Peming Hsu, May 2010
The mold rapid heating-cooling technology is applied to the thin-walled co-injection molding, to produce high-quality electronic products. In case of thin-walled co-injection molding, the flash is often generated when molten polymer flows into small gap at parting line in mold with high injection pressure or under unbalanced clamp force condition. In this study, we investigate the effect of processing conditions on flash generation using injection molding CAE. We found that the phenomenon problems can be caused from structural clamping of moving plate in co-injection molding machine. The predicted flash shape was compared with experimental result.
APPLICATION OF ULTRA HIGH SPEED INJECTION MOLDING TO SECURE DIGITAL (SD) CARD HOUSING
Pao-Lin Su , Shia-Chung Chen , Hsin-Shu Peng , Hsien-Hsun Tseng , Peming Hsu, May 2010
Ultra high speed injection molding plays a more significant role in molding thin-wall part in recent 3C products. Systematic studies on the proper molding window of Secure Digital (SD) card housing of 0.25 mm thick using ultra high speed injection molding have not yet been reported. In this study a proper molding window for SD card housing using ABS and HDPE by varying mold temperatures from 30 ? to 100 ? and injection speeds from 100 mm/sec to 1200 mm/sec was investigated in details. Molded dimension and weight were measured experimentally. It was found that higher mold temperature and faster injection speed are two critical molding parameters that leading to good moldablilty for SD card housing.
APPLICATION OF ULTRA HIGH SPEED INJECTION MOLDING TO SECURE DIGITAL (SD) CARD HOUSING
Pao-Lin Su , Shia-Chung Chen , Hsin-Shu Peng , Hsien-Hsun Tseng , Peming Hsu, May 2010
Ultra high speed injection molding plays a more significant role in molding thin-wall part in recent 3C products. Systematic studies on the proper molding window of Secure Digital (SD) card housing of 0.25 mm thick using ultra high speed injection molding have not yet been reported. In this study, a proper molding window for SD card housing using ABS and HDPE by varying mold temperatures from 30 ƒ?Ÿ to 100 ƒ?Ÿ and injection speeds from 100 mm/sec to 1200 mm/sec was investigated in details. Molded dimension and weight were measured experimentally. It was found that higher mold temperature and faster injection speed are two critical molding parameters that leading to good moldablilty for SD card housing.
FRACTURE TOUGHNESS OF PVC/ CROSS-LINKED PVC BLENDS
Obiageli B. Onovo, Andrey Beyle, Christopher C. Ibeh, May 2010
Toughening mechanisms in relation with the hierarchical structure of PVC by incorporating a cross-linked PVC based on microscopic was investigated The microscopic observations of the damage zone ahead of the notch showed that many voids initiated from primary PVC particles in the gelation of 61% . As further increase in gelation, an internal craze ahead of the local shear yield zone is observed at the tip of a notch. Brittle fracture occurred within 40wt% content of cross-linked PVC, whereas a stable cracking and/or crazing observed over 50wt% content. Nevertheless, the gelation of this sample showed 79% and the primary particles had already disappeared; the structure of craze was quite deferent form that of pure PVC. The mechanisms of yielding were not affect on hierarchical structure of PVC whereas the mechanisms of crazing was strongly affect on the hierarchical morphology.
EFFECTS OF MOLDING PARAMETERS CONTROL ON FIBER ORIENTATION AND DISTRIBUTION LEADING TO HIGH ELECTRICAL CONDUCTIVITIES OF INJECTION MOLDED BIPOLAR PLATES
S. C. Chen , M. Y. Shih , P. H. Lee , J. S. Huang , S. H. Wang , Y. H. Lin, May 2010
Electrical polymer composites for molding of bipolar plate are easily fabricated. In this study PPS filled with 50wt% carbon fiber (CF) and PPS mixed with 50wt% CF + 20wt% Graphite (GP) were used for injection molding of a bipolar plate to study the associated fiber orientation and distribution and their effects on surface conductivity under various molding conditions. The flat plates were both convectional injection molded (CIM) and injection compression molded (ICM). In-plane conductivity (IPC) and through-plane resistance (TPR) of the bipolar plates was measured. Under proper molding conditions TPR and IPC can be improved by 54% and 48% respectively in CIM whereas TPR was improved by 70% and IPC improved by 184% in ICM. IPC can reach 156S/cm when molded by ICM.
EFFECTS OF MOLDING PARAMETERS CONTROL ON FIBER ORIENTATION AND DISTRIBUTION LEADING TO HIGH ELECTRICAL CONDUCTIVITIES OF INJECTION MOLDED BIPOLAR PLATES
S. C. Chen , M. Y. Shih , P. H. Lee , J. S. Huang , S. H. Wang , Y. H. Lin, May 2010
Electrical polymer composites for molding of bipolar plate are easily fabricated. In this study, PPS filled with 50wt% carbon fiber (CF) and PPS mixed with 50wt% CF + 20wt% Graphite (GP) were used for injection molding of a bipolar plate to study the associated fiber orientation and distribution and their effects on surface conductivity under various molding conditions. The flat plates were both convectional injection molded (CIM) and injection compression molded (ICM). In-plane conductivity (IPC) and through-plane resistance (TPR) of the bipolar plates was measured. Under proper molding conditions, TPR and IPC can be improved by 54% and 48%, respectively, in CIM, whereas TPR was improved by 70% and IPC improved by 184% in ICM. IPC can reach 156S/cm when molded by ICM.
USING KNOWLEDGE-BASED MANAGEMENT TECHNOLOGY FOR AN INTEGRATED MOLD-DESIGN PROCESS
Hsuan-Liang Lin , Ming-Chang Jeng , Shia-Chung Chen, May 2010
Efficiency and quality are essential demands in mold design/making and molding industry. This study utilizes the knowledge-based concept and database driven platform combined with 3D drawing software to develop an integrated mold-design/making and molding system. Compared with standard 3D drawing-design process and knowledge management technology reduce the design lead time, possible mistakes in 3D mold building. The platform includes conceptual mold-design, core and cavity design, 3D drawing and the databases of standard building mold process and quick modifying in mold design change, etc.. It leads to the reduction of mold design cycle for cellular phone housing from 7 days to 3 days.
CALCULATION AND ANALYSIS OF MOLD COST FOR INJECTION MOLDING VIA A MOLD DESIGN NAVIGATION SYSTEM
Shia-Chung Chen , Chia-Yen Tseng , Jeng-Li Shiu, May 2010
Low cost and quality are essential demands in mold and molding manufacturing. Mold cost calculations can be classified into four parts: material manufacture overhead and profit. This research develops a navigation system that can provide a calculation and analysis of mold prices. The difference between the actual sample price and the calculated price is roughly 6%. Via the mold price navigation system customer and mold vendor engaged in detailed discussions and obtain a good mold price estimate. The system not only greatly helps the inexperienced designer but also provides a feasible mold price calculation conception and a collaborative environment for the design process.
CALCULATION AND ANALYSIS OF MOLD COST FOR INJECTION MOLDING VIA A MOLD DESIGN NAVIGATION SYSTEM
Shia-Chung Chen , Chia-Yen Tseng , Jeng-Li Shiu1, May 2010
Low cost and quality are essential demands in mold and molding manufacturing. Mold cost calculations can be classified into four parts: material, manufacture, overhead, and profit. This research develops a navigation system that can provide a calculation and analysis of mold prices. The difference between the actual sample price and the calculated price is roughly 6%. Via the mold price navigation system, customer and mold vendor engaged in detailed discussions and obtain a good mold price estimate. The system not only greatly helps the inexperienced designer but also provides a feasible mold price calculation conception and a collaborative environment for the design process.
PROCESSING AND PROPERTIES OF ELECTRO-CONDUCTIVE CARBON NANOTUBE COMPOSITES IN HIGH PERFORMANCE ENGINEERING POLYMERS
Jun Taniguchi, Noriyuki Unno, Yasuhiro Kamiya, Nobuji Sakai, Takeshi Ohsaki, May 2010
Development of electro-conductive polyamide 4.6 (PA4.6) and polyamide 4.6/poly(phenylene sulfide) blend (PA4.6/PPS) incorporating multiwall carbon nanotube (CNT) were first reported in this work. PPS/CNT was also investigated. The CNT composites exhibited electrical conductivity at remarkably low CNT content, displayed a volume electrical percolation threshold at < 0.9 wt% CNT. At only 1 wt%, all the three composites would already register  103 Ohm?úcm volume resistivity. The required surface electrical percolation to reach 107 Ohm ?ú sq-1 for the PA4.6, PPS and PA4.6/PPS blend was 1.4, 2.0 and 0.9 wt% respectively. A co-continuous morphology observed for the PA4.6/PPS blend would explain for its extremely low percolation. The melt crystallisation behavior of the polymers altered appreciably in the presence of CNT. PA4.6 crystallised at some 12 ?øC higher, from 257.5 ?øC to 269.5 ?øC. The full crystallisation half-time of PPS was reduced by nearly 2/3 from 110s to 38s, while its peak crystallising temperature was raised by some 46 ?øC from 188.5 ?øC to 235 ?øC. The small doublet melting peak of the virgin PA 4.6/PPS blend would merge into single peak in its composite that could indicate the blend compatibility was more improved in the presence of CNT. Furthermore, the PA4.6/PPS/CNT blend showed least mould shrinkage and smoothest injection moulded surface among all the composites investigated.


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