Injection Moulding Test Plaque with Defect-Mimicking Features
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Solution Overview
Problem
Existing test plaques for rheological characterization of injection-molded plastic products are featureless, failing to provide a full set of relevant data for injection molding processes, and existing test specimens for tensile testing do not capture the rheological properties necessary for injection-molded products.
Innovation Solution
Development of test specimens with spatial features that mimic common defects and geometric features of injection-molded products, allowing for more comprehensive rheological data acquisition through methods and systems that include sensors for process validation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing featureless test plaques are used for rheological characterization, then the testing process is simple and quick, but the plaques do not enable obtaining a full set of rheological data relevant to injection moulding and plastic products
Solution Approach 1:
The test plaque is divided into multiple functional zones with different spatial features (ribs, through-openings, recesses, projections) that correspond to different rheological properties and defect types. Each zone can be independently designed and measured to obtain specific rheological data relevant to injection moulding processes.
Solution Approach 2:
Different regions of the test plaque are given different local characteristics (spatial features) to represent specific defect types and geometric conditions. This allows the single test plaque to simultaneously provide data on multiple rheological properties, such as flow behavior, shrinkage, and warpage, under different local conditions.
2Measurement precision
If existing test specimens for tensile testing are used, then tensile properties can be measured, but they do not enable obtaining sufficient rheological data relevant to injection moulding
Solution Approach 1:
The test plaque is designed to serve multiple functions: it can measure rheological properties, detect defects, evaluate geometric features, and provide data on shrinkage and warpage. The same test plaque structure can be used for different types of measurements by selecting appropriate measurement zones and features, making it universally applicable to various injection moulding process evaluations.
Solution Approach 2:
The test plaque incorporates spatial features that copy or mimic common defects and geometric features found in actual injection moulded plastic products. This allows the test plaque to replicate the rheological challenges and defect patterns of real products, enabling accurate prediction and evaluation of injection moulding process performance.
3Measurement precision
If simulation software is used to predict product properties, then design and material selection can be ideally predicted, but the prediction is complex and suffers from lack of data on rheological characterization
Solution Approach 1:
The test plaque provides experimental measurement data that serves as feedback to validate and refine simulation models. By measuring actual rheological properties and defect characteristics from the test plaque, this feedback information can be used to adjust and improve the accuracy of digital twin simulations and prediction software for injection moulding processes.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
The invention relates to a test specimen (1) for rheological testing of plastic products comprising a plate body (10) from a plastic material, said plate body (10) having a first major surface (102), a second major surface opposite to the first major surface (102) and a side surface (106) connecting the first and the second major surface (104) and at least one spatial feature (12A, 12B, 14A, 14B) arranged in or on the plate body (10), each spatial feature (12A, 12B, 14A, 14B) indicative of a defect occurring in the plastic products or a geometric feature of the plastic products. The invention relates further to methods and respective systems using the test specimen, including methods and systems for testing for testing of a plastic product, for validating a rheological data set or a model of a process for manufacturing of plastic products, for determining at least one property of a plastic product to be manufactured and for manufacturing a plastic product.