Skip to main content
SpringerLink
Log in

Improvement on the surface quality of microcellular injection molded parts using microcellular co-injection molding with the material combinations of PP and PP-GF

  • Research Article
  • Published:
International Journal of Plastics Technology

Abstract

Microcellular co-injection molding technology can completely encase the poor surface of a MuCell part. Using this technology, the effects of PP and PP-GF (10-wt% GF) combinations on the surface quality were investigated. For comparators, conventional, MuCell, and co-injection molded parts were also processed using constant injection parameters and varied material combinations. The surface quality was inspected both qualitatively via visual appearance and quantitatively via surface gloss. In addition, the weight reduction was also measured to ensure a successful microcellular structure generation inside the core. The results show that microcellular co-injection molded PP/PP-GF (skin/core) is the optimal combination with 4.2% weight reduction over co-injection PP/PP-GF, a similar surface appearance and surface gloss (60.9 GU) comparable to its solid PP counterpart, and 46.7% higher surface gloss than MuCell PP-GF. In addition, its specific dimensionless surface gloss is ranked first among all material combinations.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

References

  1. Martini JE et al (1982) The production and analysis of microcellular thermoplastic foam. SPE ANTEC Tech Pap 28:674–676

    Google Scholar 

  2. Colton JS, Suh NP (1987) Nucleation of microcellular foam: theory and practice. Polym Eng Sci 27(7):500–503

    Article  CAS  Google Scholar 

  3. Kwag C, Manke CW, Gulari E (2001) Effects of dissolved gas on viscoelastic scaling and glass transition temperature of polystyrene melts. Ind Eng Chem Res 40(14):3048–3052

    Article  CAS  Google Scholar 

  4. Chen SC, Hsu PS, Lin YW, Hsu CL (2009) Measurement on viscosity of polystyrene melt dissolved with supercritical nitrogen fluid during microcellular injection molding. 67th annual technical conference of the Society of Plastics Engineers 2009 (ANTEC 2009), pp 472–476

  5. Chen SC, Liao WH, Chien RD (2012) Structure and mechanical properties of polystrene foams made through microcellular injection molding via control mechanism of gas counter pressure and mold temperature. Int Commun Heat Mass 39(8):1125–1131

    Article  CAS  Google Scholar 

  6. Sun X, Kharbas H, Peng J, Turng LS (2014) A novel method od producing lightweight microcellular injection molded parts with improved ductility and toughness. Polymer 30:1–9

    Google Scholar 

  7. Zhang Y, Li H, Hwang S (2010) Surface defects and morphology of microcellular injection molded PC parts. Polym Mater Sci Eng 26(4):127–130

    Google Scholar 

  8. Wang Y, Hu G (2011) Research progress of improving surface quality of microcellular foam injection parts. Appl Mech Mater 66–68:2010–2016. doi:10.4028/www.scientific.net/AMM.66-68.2010

    Google Scholar 

  9. Turng LS, Kharbas H (2004) Development of a hybrid solid-microcellular co-injection molding process. Int Polym Proc XIX(1):77–86

    Article  Google Scholar 

  10. Shen C, Kramschuster A, Ermer D, Turng LS (2006) Study of shrinkage and warpage in microcellular co-injection molding. Int Polym Proc XXI(4):393–401

    Article  Google Scholar 

  11. Chen SC, Lin YW, Chien RD, Li HM (2008) Variable mold temperature to improve surface quality of microcellular injection molded parts using induction heating technology. Adv Polym Tech 27(4):224–232

    Article  Google Scholar 

  12. Chen HL, Chien RD, Chen SC (2008) Using thermally insulated polymer film for mold temperature control to improve surface quality of microcellular injection molded parts. Int Commun Heat Mass 35(8):991–994

    Article  CAS  Google Scholar 

  13. Lee J, Turng LS (2004) Improving surface quality of microcellular injection molded parts through mold surface manipulation with thin film insulation. Polym Eng Sci 50(7):1281–1289

    Article  Google Scholar 

  14. Yoon JD, Hong SK, Kim JH (2004) A mold surface treatment for improving surface finish of injection molded microcellular parts. Cell Polym 23(1):39–47

    CAS  Google Scholar 

  15. Cha SW, Jae DY (2005) The relationships of mold temperatures and swirl marks on the surface of microcellular plastics. Polym Plast Technol Eng 44(5):795–803

    Article  CAS  Google Scholar 

  16. Bledzki AK, Kirschling H, Steinbichler G, Egger P (2004) Polycarbonate micro foams with a smooth surface and higher notched impact strength. J Cell Plast 40:489–496

    Article  CAS  Google Scholar 

  17. Chen SC, Hsu PS, Lin YW (2011) Establishment of gas counter pressure technology and its application to improve the surface quality of microcellular injection molded part. Int Polym Proc XXVI(3):275–282

    Article  Google Scholar 

  18. Li S, Zhao G, Wang G, Guan Y, Wang X (2014) Influence of relative low gas counter pressure on melt foaming behavior and surface quality of molded parts in microcellular injection molded process. Int Polym Proc 50(5):415–435

    CAS  Google Scholar 

  19. Ishikawa T, Taki K, Ohsima M (2012) Visual observation and numerical studies of N2 vs. CO2 foaming behavior in core-back foam injection molding. Polym Eng Sci 52(4):875–883

    Article  CAS  Google Scholar 

  20. Chen SC, Hsu PS, Hwang SS (2013) The effects of gas counter pressure and mold temperature variation on the surface quality and morphology of the microcellular polystyrene foams. J Appl Polym Sci 127(6):4769–4776

    Article  CAS  Google Scholar 

  21. Lee J, Turng LS, Dougherty E, Gorton P (2011) A novel method for improving the surface quality of microcellular injection molded parts. Polymer 52(6):1436–1446

    Article  CAS  Google Scholar 

  22. Peng J, Turng LS, Peng XF (2012) A new microcellular injection molding process for polycarbonate using water as the physical blowing agent. Polym Eng Sci 52(7):1464–1473

    Article  CAS  Google Scholar 

  23. Lee J, Turng LS, Dougherty E, Gorton P (2011) novel foam injection molding technology using carbon-dioxide-laden pellets. Polym Eng Sci 51(11):2295–2303

    Article  CAS  Google Scholar 

  24. Sun X, Turng LS (2014) Novel injection molding foaming approaches using gas-laden pellets with N2, CO2, and N2 + CO2 as the blowing agents. Polym Eng Sci 54(4):899–913

    Article  CAS  Google Scholar 

  25. Cabrera ED, Mulayana R, Castro JM, Lee J, Min Y (2013) Pressurized water pellets and supercritical nitrogen in injection molding. J Appl Polym Sci 127(5):3760–3767

    Article  CAS  Google Scholar 

  26. Xu J (2007) Methods to the smooth surface of microcellular foam in injection molding. In: ANTEC 2007 plastics: annual technical conference proceedings, vol 4, pp 2077–2081

  27. White JL, Lee BL (1975) An experimental study of sandwich injection molding of two polymer melts using simultaneous injection. Polym Eng Sci 15(7):481–485

    Article  CAS  Google Scholar 

  28. Young SS, White JL, Clark ES, Oyanagi Y (1980) A basic experimental study of sandwich injection molding with sequential injection. Polym Eng Sci 20(12):798–804

    Article  CAS  Google Scholar 

  29. Kadota M, Cakmak M, Hamada H (1999) Structural hierarchy developed in co-injection molded polystyrene/polypropylene parts. Polymer 40(11):3119–3145

    Article  CAS  Google Scholar 

  30. Watanabe D, Ishiaku US, Nagaoka T, Tomari K, Hamada H (2003) The flow behavior of core material and breakthrough phenomenon in sandwich injection molding part I: dependence on viscosity and injection speed of skin/core materials. Int Polym Proc 18(4):398–404

    Article  CAS  Google Scholar 

  31. Gomes M, Martino D, Pontes AJ, Viana JC (2011) Co-injection molding of immiscible polymers: skin-core structure and adhesion studies. Polym Eng Sci 51(12):2398–2407

    Article  CAS  Google Scholar 

  32. Peng J, Yu E, Sun X, Turng LS, Peng XF (2011) Study of microcellular injection molding with expandable thermoplastic microsphere. Int Polym Proc XXVI(3):249–255

    Article  Google Scholar 

Download references

Acknowledgements

This research was supported by R&D Center for Mold and Molding Technology, Chung Yuan Christian University, Taiwan.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Chung Yuan Christian University, Taoyuan City, Taiwan

    Edward Suhartono, Shia-Chung Chen, Yung-Hsiang Chang, Jen-An Chang & Kuan Hua Lee

  2. R&D Center for Mold and Molding Technology, Chung Yuan Christian University, Taoyuan City, Taiwan

    Edward Suhartono, Shia-Chung Chen, Yung-Hsiang Chang, Jen-An Chang & Kuan Hua Lee

Authors
  1. Edward Suhartono
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shia-Chung Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yung-Hsiang Chang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jen-An Chang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Kuan Hua Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yung-Hsiang Chang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Suhartono, E., Chen, SC., Chang, YH. et al. Improvement on the surface quality of microcellular injection molded parts using microcellular co-injection molding with the material combinations of PP and PP-GF. Int J Plast Technol 21, 239–251 (2017). https://doi.org/10.1007/s12588-017-9182-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12588-017-9182-7

Keywords

Search

Navigation