Film insert injection molding (FIM) is an increasingly popular
technique to impart decoration onto moldings. In this study, FIMs
were produced by using amorphous and crystalline polymers that were
evaluated based on their film-substrate interfacial adhesion
strength. Interfacial bonding between amorphous polymers could be
achieved at any temperature above the glass transition, though
higher temperatures are favorable to enhance diffusion rates. As
for crystalline polymers, melting of the crystalline phase in the
film was needed to create mobile molecular chains before any
significant bonding could take place. Hence, the resin temperature
should be sufficient to induce melting of the film surface.
Regardless of materials characteristics, certain criteria have to
be met to ensure good interfacial bonding. Good film-substrate
intimacy should be attained to provide a wider contact area for
interfacial diffusion. Resins with low Mw and linear chain
structures could easily diffuse across the interface and form
molecular entanglements with sufficient cooling. Hence, barrel and
mold temperatures were the most important parameters that governed
the interfacial strength during molding.
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