Decreasing the cycle time for in‐mold coating (IMC) of sheet molding compound (SMC) compression molding

Abstract

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 (t-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.

Development and Analysis of an In-Mold Coating Procedure for Thermoplastic Resin Transfer Molding to Produce PA6 Composites with a Multifunctional Surface

“…During the process, the coating is created in a closed mold, thus environmental regulations are met and the difficulties and additional costs associated with surface treatment are reduced. The coating and the product are produced directly one after the other, and no post-processing is required [30,31]. IMC can be performed by placing the coating layer in the mold or by partially opening the mold and injecting the surface material [29][30][31][32][33].…”

“…The coating and the product are produced directly one after the other, and no post-processing is required [30,31]. IMC can be performed by placing the coating layer in the mold or by partially opening the mold and injecting the surface material [29][30][31][32][33].…”