Saturday, December 18, 2004
Insert Molding Decoration Design Guideline
IMD Lens 拔模斜度設定:
IMD模具之拔模角要求除一般塑膠成型之拔模角外，因應IMD FILM之因素外觀之拔模角必須加大。
PL 以下為透明露出HOUSING----------------議修改後之PL位置
B.成品R要求：
1. 成品之形全周edge最小R角為0.3mm。
2. 有孔及深槽部份R角必須大於0.2mm。
3. 成品母模內部外觀edge最小R角為0.2mm。
C. IMD (INSERT MOLDING DECORATION) 其製程為將油墨印刷於一PE薄膜上其亦可以蒸著方式將金屬材質蒸著於PE薄膜上，成為整捲型式於成型機台加定位系統，將薄膜之印刷位置與模腔內欲印位置對位後，與塑料成型，成型後成型品與油墨結合但與薄膜分離繼續下一模之成型動作，成行後的成品經由UV照射後表面產生硬化而完成。其與IML/IMR最大不同為IMD印刷油膜位於成型品表層，而IML其油膜位於PC薄膜及塑料之中間。
IMD模具之拔模角要求除一般塑膠成型之拔模角外，因應IMD FILM之因素外觀之拔模角必須加大。
A.公模PL拔模角要求3~5°，公模尺寸內縮0.1mm，尺寸如附圖。
B.成品外觀拔模角不得為90°直角，建議角度越大越好最小為15°，edge均得加R角，主要為IMD FILM披覆時不會肇成IMD FILM裂痕。
IMD SAMPLE (Dbtel Corp. M9)
IMD Lens Parting Line:
PART LINE位置：因公母模反置PL必須至於母模R角結束下方0.3mm位置，此為模具製程限制，此位置亦為IMD油墨覆蓋結束的分界。PL關係了外觀配合時的種種表現，因其PL位於母模R角結束下方0.3mm位置屬於淺層位置，公模處則為透明塑膠材質，若PL高於配合件之外觀將發生此透明塑膠材質被看見，可能成為外觀上的缺點。同樣的問題亦會發生於IML模具上。針對此問題於ID的外觀造型上必須特別注意此點於設計前與ID溝通。
PART LINE位置：因公母模反置PL必須至於母模R角結束下方0.3mm位置，此為模具製程限制，此位置亦為IMD油墨覆蓋結束的分界。PL關係了外觀配合時的種種表現，因其PL位於母模R角結束下方0.3mm位置屬於淺層位置，公模處則為透明塑膠材質，若PL高於配合件之外觀將發生此透明塑膠材質被看見，可能成為外觀上的缺點。同樣的問題亦會發生於IML模具上。針對此問題於ID的外觀造型上必須特別注意此點於設計前與ID溝通。
成品R角0.3mm，PL於R結束後0.3mm
PL 以下為透明露出HOUSING----------------議修改後之PL位置
其它注意事項:
A.成品最小肉厚：平面t=1.0mm. ，非平面t=1.2mm以下容易發生thermo shack 後成品變形及gate有縮水現象。
A.成品最小肉厚：平面t=1.0mm. ，非平面t=1.2mm以下容易發生thermo shack 後成品變形及gate有縮水現象。
B.成品R要求：
1. 成品之形全周edge最小R角為0.3mm。
2. 有孔及深槽部份R角必須大於0.2mm。
3. 成品母模內部外觀edge最小R角為0.2mm。
C. IMD (INSERT MOLDING DECORATION) 其製程為將油墨印刷於一PE薄膜上其亦可以蒸著方式將金屬材質蒸著於PE薄膜上，成為整捲型式於成型機台加定位系統，將薄膜之印刷位置與模腔內欲印位置對位後，與塑料成型，成型後成型品與油墨結合但與薄膜分離繼續下一模之成型動作，成行後的成品經由UV照射後表面產生硬化而完成。其與IML/IMR最大不同為IMD印刷油膜位於成型品表層，而IML其油膜位於PC薄膜及塑料之中間。
IMD 製程如圖所示 (NISSHA Corp.)
# posted by Eli Huang @ 12/18/2004 10:48:00 AM 
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