In-Mold Decoration Simulation for Molding Condition Optimization

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Solution Overview

Problem

The existing injection molding processes for in-mold decoration require numerous trial operations and a long setup time due to their dependence on operator expertise, and they struggle with accurately simulating the complex interactions within the mold cavity, leading to inconsistent product quality.

Innovation Solution

A computer-aided engineering (CAE) simulation method is employed to control a molding machine, which involves specifying a simulating domain, performing first and second molding simulations to generate velocity and temperature distributions for both the molding material and decorating film, and using these simulations to set boundary conditions for actual molding, thereby optimizing the molding conditions and reducing setup time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional trial molding operations are used to set molding conditions, then operator expertise can be utilized, but the setup time becomes excessively long and productivity decreases

Engineering Contradiction:

Improvemolding condition accuracyVSAvoidsetup time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent performs preliminary CAE simulations to predict molding conditions and decorating film behavior before actual production. The simulation results are used to pre-determine optimal molding parameters, eliminating the need for extensive trial operations and significantly reducing setup time while maintaining accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates a virtual copy of the molding process through CAE simulation. This digital model replicates the physical molding process, allowing virtual experimentation and optimization without consuming actual materials or machine time, thus accelerating the setup process while ensuring reliable molding conditions.

Inventive Principle:

Principle #26Copying

2Productivity

If simple simulation models are used, then computing time is reduced, but the accuracy of simulating complex interactions within the mold cavity deteriorates

Engineering Contradiction:

Improvecomputing timeVSAvoidsimulation accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent segments the simulation domain into distinct regions: a first portion for the molding material and a second portion for the decorating film. This segmentation allows the use of simplified models in each region while capturing the essential physics, reducing overall computing time without sacrificing the accuracy of material-film interactions at the interface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different levels of simulation complexity to different regions. The first portion uses a simplified model for bulk material behavior, while the second portion uses a more detailed model for the decorating film. This local quality approach optimizes computing resources while maintaining accuracy where it matters most.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach allows for more accurate and rapid simulation of molding phenomena, significantly reducing computing time and improving the consistency of in-mold decorated articles by optimizing molding conditions and stabilizing the molding process.

Implementation Method 1

performing a first molding simulation executed on the controlling module to generate a velocity distribution of the fluid molding material in a first portion of the simulating domain

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

performing a second molding simulation executed on the controlling module to generate a velocity distribution of the solid decorating film in a second portion of the simulating domain

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

the second molding simulation is performed using the velocity distribution of the fluid molding material to set a boundary condition of the second portion

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10864667B2Molding system for preparing an in-mold decorated article

Publication Date: 2020.12.15 CORETECH SYST CO LTD

AI summary

A molding system comprises a mold, a molding machine, a computing apparatus, and a controller. The computing apparatus is programmed to perform a first simulation to generate a velocity distribution and a temperature distribution of the molding material in a first portion of a simulating domain and a second simulation to generate a melting distribution of the solid decorating film in a second portion of the simulating domain, wherein the simulating domain corresponds to the mold cavity. The first molding simulation is to performed using a molding condition of the molding machine to set a boundary condition of the first portion, and the second molding simulation is performed using the velocity distribution and the temperature distribution of the molding material to set a boundary condition of the second portion.