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Fabrication of lightweight polymer products with excellent mechanical properties using a novel double-sided in-mold decoration combined with fiber-reinforced microcellular injection molding process

Journal of materials research and technology, 2024-01, Vol.28, p.4289-4298 [Peer Reviewed Journal]

2024 The Authors ;ISSN: 2238-7854 ;DOI: 10.1016/j.jmrt.2024.01.045

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  • Title:
    Fabrication of lightweight polymer products with excellent mechanical properties using a novel double-sided in-mold decoration combined with fiber-reinforced microcellular injection molding process
  • Author: Yu, Shengrui ; Wang, Kai ; Xu, Lei ; Song, Senzhen ; Yang, Jiangen ; Han, Wen ; Zhou, Huamin
  • Subjects: Cellular structure ; Fiber orientation tensor ; Glass fiber ; In-mold decoration ; Microcellular molding
  • Is Part Of: Journal of materials research and technology, 2024-01, Vol.28, p.4289-4298
  • Description: This paper introduces a novel molding process known as the double-sided in-mold decoration combined with fiber-reinforced microcellular injection molding (DS-IMD/FR-MIM) process. This process utilizes supercritical fluids to grow a microcellular structure for a lightweight product and adds glass fibers into polymer particles to reinforce mechanical properties. Concurrently, double-sided in-mold decoration (DS-IMD) technique provides a symmetric temperature field for melts during filling stage and high surface quality for parts after cooling. Tensile splines are simulated and tested to examine the impacts of various in-mold decoration methods on the melt temperature, freezing layer fraction, fiber orientation, cellular morphology and distribution, and mechanical properties. Applied splines include undecorated and fiber-reinforced microcellular injection molding (FR-MIM) spline, single-sided in-mold decoration combined with fiber-reinforced microcellular injection molding (SS-IMD/FR-MIM) spline, and DS-IMD/FR-MIM spline. Additionally, a flexural spline is used to test its flexural strength and surface quality. The results show that DS-IMD/FR-MIM process provides slower freezing speed and better foaming effect than FR-MIM process. It also generates more symmetric cellular distribution and more orderly fiber distribution than SS-IMD/FR-MIM process. DS-IMD/FR-MIM splines have high surface quality on decorated surfaces and 10.2 % weight loss. By comparison with FR-MIM and SS-IMD/FR-MIM splines, DS-IMD/FR-MIM splines increase an elongation at break by 24.3 % and 14.8 %, respectively. This paper contributes a feasible approach and theoretical groundwork for the fabrication of lightweight products with excellent mechanical strength and appearance.
  • Publisher: Elsevier B.V
  • Language: English
  • Identifier: ISSN: 2238-7854
    DOI: 10.1016/j.jmrt.2024.01.045
  • Source: GFMER Free Medical Journals
    DOAJ Directory of Open Access Journals
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