플라스틱 중공부품의 일체화 성형을 위한 인몰드 펀칭 공정기술에 관한 연구

이성희 한국금형공학회 2021 한국금형공학회지 Vol.15 No.4

A study on in-mold punching technology for hole piercing during molding of hollow plastic parts wasconducted. Considering the non-linearity of the HDPE plastic material, mechanical properties were obtained according tothe change in temperature and load speed. A standard specimen for the in-mold punching test was designed to implementthe in-mold punching process, and the specimen was obtained through injection molding. In order to analyze the influenceof process variables during in-mold punching, an in-mold punching mold capable of controlling variables such astemperature and support pressure of the specimen was designed and manufactured. Mold heating characteristics wereconfirmed through finite element analysis, and punching simulations for changes in process conditions were performed toanalyze punching characteristics and reflected in the experiment. Through simulations and experiments, it was found thatthe heating temperature, punch shape, punching speed, and pressure of the back side of the specimen were very importantduring in-mold punching of HDPE materials, and optimal conditions were acquired within a given range

3차원 곡면부의 인몰드 사출성형공정에 관한 연구

황지은(Ji-Eun Hwang),이동욱(Dong-Wook Lee),김종순(Jong-Soon Kim),강태호(Tae-Ho Kang),김인관(In-Kwan Kim),김영수(Young-Soo Kim) 한국기계가공학회 2006 한국기계가공학회 춘추계학술대회 논문집 Vol.2006 No.-

In-mold injection molding system is generally an advanced version of the injection molding system. The injection, printing and coating processes of In-mold injection molding take place simultaneously. The technology is mostly used in home appliances, electronic goods and cell phones. For this research we applied the In-mold technique for injection molding and process of 3D nurb-surfaces. We performed the computer simulation of injection molding to optimize the In-mold processes and identified the credibility of the products through performance evaluation.

Experimental Study on the Processing Conditions of In- Mold Coating for Injection-Molded Plates

김동미,이호상 한국정밀공학회 2016 International Journal of Precision Engineering and Vol.17 No.10

In-Mold Coating (IMC) is novel coating method which achieves simultaneous injection molding and surface coating. In this paper, a mold for in-mold coating experiments was fabricated, which consisted of an overflow area, a coating channel, and sealing edges. The coating material used was two-component polyurethane with good transparency, high glossy, durability, and scratch resistance. The effects of the processing conditions of the in-mold coating on the bubbles and mixing characteristics in the injection molded plates were investigated. The bubbles that appeared over the substrate surface decreased, as the injected weight of the coating material increased. On the other hand, the bubbles increased with an increase of mass-flow rate. When the discharged flow rate was low, inhomogeneous surfaces appeared due to the poor mixing between polyol and isocyanate. It was found that the nozzle pressure of more than 180 bar was required to achieve uniform mixing.

사출금형 안에서 코팅을 위한 충돌혼합에 관한 해석

김슬우,이호상 한국금형공학회 2019 한국금형공학회지 Vol.13 No.4

In-mold Coating is a method that can simultaneously perform injection molding and surface coating in injection mold. The material used for coating is two-component polyurethane which is composed of polyol and isocyanate. L-type mixing head can be used to mix polyol and isocyanate uniformly, and inject them inside the mold cavity. The surface quality of the injection molded products by using in-mold coating depends on the mixing uniformity between main agent and hardener. In this study, flow analysis was performed to design a mixing head for uniform mixing of two-component polyurethane. Especially the effects of design parameters of mixing head on mixing uniformity and nozzle pressure were investigated. The parameters of mixing head were mixing chamber diameter, cleaning cylinder diameter, nozzle alignment angle in the horizontal and vertical direction, and cleaning piston position. It was found that optimal design values were mixing chamber diameter of 3.5 mm, cleaning cylinder diameter of 5.0 mm, nozzle horizontal/vertical alignment angles of 140°/160°, and cleaning piston position of 1.8 mm. The optimal values would be used to develop a two-component mixing head achieving an uniform mixing for in-mold coating.

IMD 공정 중 필름 변형 특성 파악을 위한 사출 및 필름성형 간 연계해석

윤종혁(J.H. Yoon),허남건(N. Hur),배아현(A.H. Bae),이태희(T.H. Lee) 한국전산유체공학회 2013 한국전산유체공학회지 Vol.18 No.3

In various manufacturing industries, an in-mold decoration (IMD) process for plastic objects is widely utilized because a film forming and an injection molding processes run simultaneously. In the present study, the deformation of polymer film and filling of resin in the IMD process were numerically investigated to evaluate the quality of the plastic object formed by the IMD process, which consists of thermoforming and injection molding processes. To obtain the initial shape of the polymer film during the injection molding process, the deformation of the polymer film in the thermoforming process was pre-formed using the vacuum conditions to attach the film to a cavity. Since the properties and deformation of polymer film are greatly affected by the behavior of polymer resin being injected into a mold cavity, numerical simulations for the injection molding and film forming were performed with one-way coupling method. The results showed that the injected resin could lead to the tearing of the polymer film in local regions near the corners. In order to verify the proposed numerical methodology, the numerical results of the deformation patterns printed on the initial polymer film were compared with the experimental data. The proposed methodology to couple film forming analysis with injection molding analysis can be used to predict the deformation of film in IMD process.

자동차 암레스트의 인몰드코팅에 관한 실험적 연구

박종락(Jong-Rak Park),이호상(Ho-Sang Lee) 대한기계학회 2014 대한기계학회 춘추학술대회 Vol.2014 No.11

Mold design for in-mold coating were carried out in order to achieve simultaneous coating and injection molding of an automotive armrest. The developed mold consists of two molds and one sliding plate. The first mold includes a movable mold piece and a first fixed mold piece for injection molding of a substrate. On the substrate surface near a parting line, sealing edges were considered for forming a seal projection. The second mold includes the movable mold piece and a second fixed mold piece for forming the coating. The mold enables coating on the substrate surface after injection molding. The materials used were PC/ABS for substrate and 2-component Polyurethane for coating. The experiments were conducted by changing the flow rate in order to investigate mixing characteristics. As the flow rate increased, the mixing was more improved. And the bubbles appeared over the substrate surface decreased with an increase of the weight of injected coating material.

사출성형을 이용한 마이크로 채널의 패키징 공정에 관한 연구

Kwan-Hee Lee(이관희),Duck-Soo Park(박덕수),Jae Sung Yoon(윤재성),Yeong-Eun Yoo(유영은),Doo-Sun Choi(최두선),Sun-Kyoung Kim(김선경) 대한기계학회 2008 대한기계학회 춘추학술대회 Vol.2008 No.11

A novel in-mold packaging process has been developed to manufacture devices with closed channels. In this unified process, fabrication of open channels and forming the rigid cover on top of them are sequentially integrated in the same mold. The entire process is comprised of two phases. In the first phase, the open channels are fabricated under an exquisitely controlled temperature and pressure using the conventional micro injection molding technology. In the second phase, the closed channels are fabricated by conducting the injection molding process using the molded structure with the open channels as a mold insert. As a result, the in-mold technology can eliminate the bonding processes such as heating, ultrasonic or chemical processes for cohesion between the channel and the cover, which have been required in conventional methods.

The Development of an Automatic Molten Metal Supplier for an Aluminum Thermal Furnace

이준호 한국생산제조학회 2009 한국생산제조학회지 Vol.18 No.5

The objective of this development project is to localize an automatic molten metal supplier that has been distributed by WESTOMAT, Germany, throughout the world. To achieve this purpose, an energy-saving pressurized dosing furnace and molten metal differential pressure control system that is able to automatically supply a determined quantity of aluminum molten metal were developed. The localized equipment was installed in a site. Also, the results of the test operation of this equipment can be summarized as follows: It was able to improve the productivity because there were small decreases in supplying speeds and small losses in wastes compared to the existing mechanical molten metal supplier. Also, it was able to minimize the cost in maintenances due to the direct application of high temperature molten metals to molds. In addition, there were small energy losses due to the use of high thermal insulators compared to the existing reverberating furnace and able to prolong the life-time of furnaces and produce good quality nonferrous metals because it represented small carbon refractories and alumina in applied molten metals. Furthermore, it demonstrated no particular differences by objectively comparing it with the product by WESTOMAT. The objective of this development project is to localize an automatic molten metal supplier that has been distributed by WESTOMAT, Germany, throughout the world. To achieve this purpose, an energy-saving pressurized dosing furnace and molten metal differential pressure control system that is able to automatically supply a determined quantity of aluminum molten metal were developed. The localized equipment was installed in a site. Also, the results of the test operation of this equipment can be summarized as follows: It was able to improve the productivity because there were small decreases in supplying speeds and small losses in wastes compared to the existing mechanical molten metal supplier. Also, it was able to minimize the cost in maintenances due to the direct application of high temperature molten metals to molds. In addition, there were small energy losses due to the use of high thermal insulators compared to the existing reverberating furnace and able to prolong the life-time of furnaces and produce good quality nonferrous metals because it represented small carbon refractories and alumina in applied molten metals. Furthermore, it demonstrated no particular differences by objectively comparing it with the product by WESTOMAT.

도토주조법의 복원을 위한 기록 및 실험과정의 재검토

김성수,이승철 한국서지학회 2010 서지학연구 Vol.46 No.-

이 연구는 「후생록」 鑄字(조) ‘俗法鑄字’(항)에 연원한 도토주조법에 관하여 그 불충분한 기록내용을, 동전의 주조와 관련한 주전법(鑄錢法)에서 ‘전범(錢範)의 제작과정’ 등을 원용하여, ‘속법주자’의 기록을 이론적으로 보완하여 기술하고자 하였다. 본론에서 분석한 연구 결과를 요약하면 다음과 같다. 첫째, 도토판에서 글자의 음각화(陰刻化) 문제는, 양각의 목활자를 활용하여 도토판에서 각 글자를 압착(壓刻)하여 음각화하는 방안이 가장 효율적임을 파악하였다. 둘째, 「후생록」의 기록에서 누락된 ‘활자의 높이(몸체)’ 문제는, 도토판에 목활자를 함몰될 정도로 압착(印着)할 경우, 도토판에 목활자 높이만큼의 깊이가 주어지고, 바로 이 깊이 부분에 쇳물이 고이면, 금속활자의 몸체가 자연적으로 생성되기 때문에, 활자 몸체의 주성(鑄成)의 문제를 해결하였다. 셋째, ‘쇳물 주입과 관련한 주형(鑄型)의 문제’는, 금속활자의 주조와 같은 요주(澆鑄)공예에서는 청동기시대부터 반드시 쌍틀(兩面) 거푸집을 사용하였음에 유념하면, 도토주조법에서도 마땅히 쌍틀 형식의 도토판 거푸집을 사용하여야 하며, 주형 속에 탕도 및 세탕도를 마련하여야 비로소 금속활자의 원만한 주조가 이루어질 것임을 논증하였다. This research attempted to describe the method of casting metal types with clay, documented in the article of 'casting metal types in the private sector' in 'Husaengnok'. Since the record of this article is insufficient, an attempt was also made to complement theoretically its record by referring to 'the process of casting a mold for coins' which was used for producing coins. The major findings of this research are as follows:First, in order to engrave characters intaglio on a clay mold, it is best to press wooden characters carved in relief on a clay mold. Second, the method of dealing with the height of characters, not recorded in 'Husaengnok' was figured out. If wooden characters are pressed deep enough on a mold and then later pulled out, the clay mold could have spaces with the shape and depth of those wooden characters. When melted metals are poured into those spaces, the bodies of metal characters are formed. Third, it is confirmed that a double-sided mold and the presence of a regular as well as minute conduits inside the mold are required for melted metals to be poured. This kind of a double-sided mold was used for casting various metal products since the Bronze Age in history.

마이크로 인몰드 공정기술 기반 전자소자 제조 및 응용

김성현,권영우,홍석원 한국마이크로전자및패키징학회 2023 마이크로전자 및 패키징학회지 Vol.30 No.2

In the current era of the global mobile smart device revolution, electronic devices are required in all spaces that people interact with. The establishment of the internet of things (IoT) among smart devices has been recognized as a crucial objective to advance towards creating a comfortable and sustainable future society. In-mold electronic (IME) processes have gained significant industrial significance due to their ability to utilize conventional high-volume methods, which involve printing functional inks on 2D substrates, thermoforming them into 3D shapes, and injection-molded, manufacturing low-cost, lightweight, and functional components or devices. In this article, we provide an overview of IME and its latest advances in application. We review biomimetic nanomaterials for constructing self-supporting biosensor electronic materials on the body, energy storage devices, self-powered devices, and bio-monitoring technology from the perspective of in-mold electronic devices. We anticipate that IME device technology will play a critical role in establishing a human-machine interface (HMI) by converging with the rapidly growing flexible printed electronics technology, which is an integral component of the fourth industrial revolution. 전 세계적 모바일 스마트 기기 혁명은 사람이 접하는 모든 공간에서 독립된 형태의 전기회로를 요구하고 있으며, 전자기기간 연결된 사물인터넷의 구현은 사용자 측면에서 운용이 쉽고 지속 가능한 디지털 생태계 인프라 구축에서매우 중요한 위치를 차지하고 있다. 이러한 기술은 자동차 전장품, 가정용 가전제품 및 웨어러블 기기의 생산 기술 발전으로 이어지고 있으며, 특히 최근 소개된 인몰드 전자기기(in-mold electronics, IME)는 기존의 대량 공정의 장점을 극대화할 수 있는 기술로 대두되고 있다. 이 기술은 평평한 2차원 기판에 기능성 잉크를 인쇄하고, 3차원 형상으로 열/사출 성형하여 경량화 및 저비용으로 장치를 생산해내는 경제성 강점을 이유로 산업적인 가치를 평가받고 있다. 본 논문에서는인몰드 전자 장치의 제조기술 및 응용 측면에 대한 가장 최신의 국내외 연구 그룹에서 제안된 기술 개발을 소개하고자한다. 신체 표면상에서 독립된 형태의 바이오센서 전자소자의 운용을 위한 생체 모사 기술, 에너지 소자, 생체신호 모니터링 센서들을 인몰드 기술로 구현하는 기술 및 장치 구성은, 4차 산업혁명과 함께 성장 중인 유연인쇄전자 기술과 융합되어 회로 기판 제조기술의 혁신을 가져올 것으로 기대된다.