Abstract
A Gloss defect on high-gloss injection-molded surfaces are difficult to control. This paper proposes a control methodology for a gloss defect. The maximum replication factor (RFmax) is an index representing the effect of the molding conditions on the surface gloss. As RFmax increases, the surface gloss is stabilized due to the maximized replication of the mold surface. The process window of the influencing parameters for obtaining a stable surface gloss is predicted by the range of RFmax. The predicted process window suggests specific molding conditions for controlling the gloss defect. Experiments show that the surface gloss is stabilized, and the gloss defect owing to the fluctuation of the filling conditions is suppressed in the predicted process window for poly(acrylonitrile-co-butadiene-co-styrene) and polycarbonate. The novel methodology can be applied to optimize injection-molding technologies, such as sequence valve gating and rapid heat cycle molding.
Similar content being viewed by others
References
Agassant, J.F., P. Avenas, P.J. Carreau, B. Vergnes, and M. Vincent, 2017, Polymer Processing: Principles and Modeling, 2nd ed., Hanser Publications, Cincinnati.
Alexander-Katz, R. and R.G. Barrera, 1998, Surface correlation effect on gloss, J. Polym. Sci., Part B: Polym. Phys. 36, 1321–1334.
ASTM International, 2003, ASTM D2457-03 Standard test method for specular gloss of plastic films and solid plastics, Annu. Book ASTM Stand. 08.01.
ASTM International, 2003, ASTM D790-03 Standard test method for flexural properties of unreinforced and reinforce plastics and electrical insulating materials, Annu. Book ASTM Stand. 08.01.
ASTM International, 2004, ASTM D4449-90 Standard test method for visual evaluation of gloss differences between surfaces of similar appearance, Annu. Book ASTM Stand. 06.01.
ASTM International, 2008, ASTM D523-08 Standard test method for specular gloss, Annu. Book ASTM Stand. 06.01.
Autodesk Pty. Ltd, 2019, Moldflow Material Database.
Berger, G.R., D.P. Gruber, W. Friesenbichler, C. Teichert, and M. Burgsteiner, 2011, Replication of stochastic and geometric micro structures-aspects of visual appearance, Int. Polym. Process. 26, 131–322.
Bott, J., 2012, Do you still get stubborn surface defects, even with sequential valve gating?, Plast. Technol. 58, 26–27.
Carslaw, H.S. and J.C. Jaeger, 1959, Conduction of Heat in Solids, 2nd ed., Oxford University Press, Oxford.
Gim, J.-S., J.-S. Tae, J.-H. Jeon, J.-H. Choi, and B.-O. Rhee, 2015a, Detection method of filling imbalance in a multi-cavity mold for small lens, Int. J. Precis. Eng. Man. 16, 531–535.
Gim, J., J. Tae, J. Jeon, E. Han, B. Kim, and B. Rhee, 2015b, The real-time determination algorithm of mold temperature stabilization, Proc. ANTEC2015, Orlando, USA.
Gim, J. and B. Rhee, 2020, Generation mechanism of gloss defect for high-glossy injection-molded surface, Korea-Aust. Rheol. J. 32, 183–194.
Goodship, V., 2004a, Troubleshooting Injection Moulding 15, Rapra Technology Limited, Shropshire.
Goodship, V., 2004b, Practical Guide to Injection Moulding, Rapra Technology Limited, Shropshire.
Gruber, D.P., M. Buder-Stroisznigg, G. Wallner, B. Strauss, L. Jandel, and R.W. Lang, 2008, A novel methodology for the evaluation of distinctness of image of glossy surfaces, Prog. Org. Coat. 63, 377–381.
International Organization for Standardization, 2014, ISO 2813: 2014(E) Paints and varnishes — determination of gloss value at 20 degrees, 60 degrees and 85 degrees, Geneva, Switzerland.
Jeon, J., M. Kim, B. Rhee, J. Chio, E. Park, and K. Jung, 2017, A study on the halo surface defect of injection molded products, Proc. ANTEC2017, Anaheim, USA.
Konica Minolta Sensing Americas Inc., 2019, Understanding gloss standards & units, https://sensing.konicaminolta.us/blog/understanding-gloss-standards-units/.
Lee, J. and L.-S. Turng, 2010, Improving surface quality of microcellular injection molded parts through mold surface temperature manipulation with thin film insulation, Polym. Eng. Sci. 50, 1281–1289.
Lee, J., L.-S. Turng, E. Dougherty, and P. Gorton, 2011, A novel method for improving the surface quality of microcellular injection molded parts, Polymer 52, 1436–1446.
Li, J., T. Li, Y. Jia, S. Yang, S. Jiang, and L.-S. Turng, 2018, Modeling and characterization of crystallization during rapid heat cycle molding, Polym. Test. 71, 182–191.
Li, X.-P., G.-Q. Zhao, Y.-J. Guan, and M.-X. Ma, 2009, Optimal design of heating channels for paid heating cycle injection mold based on response surface and genetic algorithm, Mater. Design 30, 4317–4323.
Oliveira, M.J., A.M. Brito, M.C. Costa, and M.F. Costa, 2006, Gloss and surface topography of ABS: a study on the influence of the injection molding parameters, Polym. Eng. Sci. 46, 1394–1401.
Rhopoint Instruments Ltd., 2017, What difference in gloss units is visible to the human eye?, https://www.rhopointinstruments.com/faqs/what-difference-in-gloss-units-is-visible-to-the-human-eye/.
Seo, K., M. Kim, and D.H. Kim, 2013, Validity of the equations for the contact angle on real surfaces, Korea-Asust. Rheol. J. 25, 175–180.
Suhartono, E., H.-S. Chiu, C.-C. Hsu, C.-C. Wang, C.-W. Wang, and N. Pavan, 2017, Predict and solve stress mark on product’s cosmetic surface using controlled sequential valve gating simulation, Proc. ANTEC2017, Anaheim, USA.
Tae, J., J. Kim, J. Gim, H. Park, and B. Rhee, 2013, Evaluation of heat transfer conditions to the mold temperature stabilization in the injection molding process, Proc. ANTEC2013, Cincinnati, USA.
Tredoux, L., I. Satoh, and Y. Kurosaki, 2000, Investigation of wavelike flow marks in injection molding: a new hypothesis for the generation mechanism, Polym. Eng. Sci. 40, 2161–2174.
Wang, G., G. Zhao, H. Li, and Y. Guan, 2009, Research on a new variotherm injection molding technology and its application on the molding of a large LCD panel, Polym.-Plast. Technol. Eng. 48, 671–681.
Yoshii, M., H. Kuramoto, T. Kawana, and K. Kato, 1996, The observation and origin of micro flow marks in the precision injection molding of polycarbonate, Polym. Eng. Sci. 36, 819–826.
Yuan, Z., D. Ward, and M. Prey, 2014, Application and simulation of velocity-controlled valve gates, Autodesk University, Las Vegas, USA.
Yuan, Z., D. Astbury, F.S. Costa, D. Ward, and M. Prey, 2015, Simulation and validation of mold filling with velocity controlled valve gates, Proc. ANTEC2015, Orlando, USA.
Acknowledgments
This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government (MSIT) (No. NRF-2018R1A5A1024127). The authors thank LG Chem Ltd. and Lotte Advanced Materials Co., Ltd., the Republic of Korea, for supplying the necessary materials.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Gim, J., Rhee, B. Control of gloss defect on high-gloss injection-molded surfaces. Korea-Aust. Rheol. J. 33, 133–141 (2021). https://doi.org/10.1007/s13367-021-0012-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13367-021-0012-2