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In-Mould Decoration of Plastics
Rapra Technology Ltd, June 2002, Pages: 122
Many plastic components need to have a surface finish applied before use. This can act as a decorative layer, a protective layer, to smooth out surface defects, or to alter surface properties (for example, to enhance adhesion). If this surface effect is applied during the moulding process, it can reduce time, space, material and machinery requirements. It also allows processors to supply complete systems, rather than just moulded components. In-mould decoration techniques include the in-mould application of film, in-mould priming, in-mould labelling and the injection of paints into the mould.
In-mould decoration generally requires additional equipment, which can be expensive. Design is also critical for success. These factors need to be taken into consideration in corporate planning.
In-mould films are prepared by multi-layer extrusion or solvent casting. They can be single colour or highly patterned with detailed graphics. They are stretched across a mould prior to injection, compression or blow moulding to produce a variety of decorative effects. This technique allows for great design flexibility and permits increased customer personalisation of products such as cars and mobile phones. Changing design between moulds is as simple as changing a roll of film. Film preparation is also discussed in this review.
Coatings comprising thermoplastic, pseudo-thermoplastic and uncured thermosetting materials can be injected or extruded into a mould. Here they act as paints in compression injection moulding and co-injection moulding. An additional benefit is that in-mould painting can reduce the release of volatile organic compounds (VOCs) into the atmosphere, which is a common problem in paint shops.
In-mould labelling can eliminate the requirement for adhesive. In the first example of this practice, paper labels for ice cream container lids were inserted into the mould prior to injection. Labels can also be applied as film and made from the same plastic material as the component to facilitate bonding and create a continuous surface effect, i.e., the label becomes an integral part of the product.
These techniques have widespread use in the plastics industry and the marketplace is expanding. The car and mobile phone industries, packaging and toys are examples of key areas for growth.
Many new developments are taking place in this field. The indexed summaries of papers from the polymer library that are included with this review include a number of key patents. This reference section also provides a good indicator of the key companies involved in this area and the current applications of this technology.
The emphasis of this review is on practical applications of the techniques of in-mould decoration including advantages and disadvantages. This book provides an excellent source of information about a developing area of moulding, which will allow processors to add value to products and compete in the marketplace.
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