In mould painting using thermoset powder coating and thermoplastic substrate in closed tool injection moulding

Abstract

In mould decoration (IMD) is attractive because a fully, or partially, decorated component is produced directly from the moulding process, with reduced emissions at lower process costs when compared to traditional techniques. A new IMD process has been developed to produce a painted component direct from the injection moulding tool. This incorporates the pressure spraying of thermoset powders through a valve into a closed mould. The residual heat of the tool initially softens the thermoset. The high temperature of thermoplastic polymer injected in a standard injection moulding subsequently cures the thermoset. The resultant product combines both thermoplastic and thermoset in a single injection moulding cycle. This paper presents frames from high speed video capture of powder mould filling and the results of INSPIRE (in mould spray painting, impact reduced on the environment) initial injection moulding using thermoset polyester and acrylonitrile butadiene styrene (ABS). The parameters that affect material distribution are examined and discussed. Similarities to the coinjection moulding process are noted.