Decreasing the Cycle Time for In-Mold Coating Compression Molding

• Published in: Polymer engineering and science Vol. 59; no. 6; pp. 1158 - 1166
• Main Authors: Bhuyan, Mohammad S.K, Ko, Seunghyun, Villarreal, Maria G, Straus, Elliott J, James, Lee, Castro, Jose M
• Format: Journal Article
• Language: English
• Published: Society of Plastics Engineers, Inc 01.06.2019
• Subjects: Bonds (Securities); Coatings; Hydroquinone; Medical research; Plastic automotive parts; Polymer industry; Polymers; Production processes; Quinones; Thermosetting composites; United States
• ISSN: 0032-3888; 1548-2634
• DOI: 10.1002/pen.25095

In-mold coating (IMC) is a thermosetting liquid applied to compression molded sheet molding compound (SMC) exterior automotive or truck body panels as an environmentally friendly primer to improve surface quality and make the part conductive for subsequent electrostatic painting. The IMC is injected onto the surface of the SMC then cures and bonds to provide a smooth conductive and protective surface. In IMC as in many other reactive polymer processes, to have short cycle time while maintaining adequate flow time and pot life is required. This allows enough time to fill the mold before solidification. In this study, the effect of inhibitor (p-benzoquinone), initiator (f-butyl peroxybenzoate), and mold temperature on the flow and cure time of IMC materials has been experimentally investigated using differential scanning calorimeter. A cure model is developed based on experiments to predict inhibition and cure time. A multiple criteria optimization method was employed to identify the setting parameters of the controllable process variables that provide the best compromise (Pareto frontier [PF]) between flow and cure time. The analysis shows that simultaneous addition of initiator and inhibitor allows the molding to be performed at a higher temperature, which moves the PF toward the ideal location. Hence, minimizes the cure time and maximizes the flow time simultaneously.