Against the backdrop of transformation and upgrading in the injection molding industry, how to achieve cost reduction and efficient production while ensuring performance is becoming a core issue of concern for customers.
In response to this demand, the long glass fiber online injection molding composer (IMC) process is becoming an important development direction in the field of high-performance injection molding,Through the combination of material innovation and CAE simulation technology, Boru International has further unleashed the potential of IMC technology and accelerated its application in the lightweight use of plastic instead of steel in new energy vehicles.
IMC process:Reshaping the traditional injection molding process
Traditional long glass fiber injection molding usually requires multiple processes such as modified granulation, drying, logistics transportation, secondary drying, injection molding, etc., which not only have complex processes and high costs, but may also cause material performance loss.IMC process breaks this mode and realizes "one-step" production:
No need to purchase long glass fiber reinforced particles;
raw materialPolypropylene（
PP）+Long glass fiber online precise proportioning;
After mixing and homogenization, the plastic is directly injected into the mold for molding;
Realize continuous high cycle production.
This innovative model brings significant advantages:
Cancel intermediate processes such as granulation, drying, packaging, and transportation;
Significantly reduce overall costs and energy consumption;
Better retention of long fiber length to enhance product performance;
Support flexible adjustment of glass fiber ratio to meet diverse needs.
IMC technology is becoming the mainstream trend for high-performance, long glass fiber injection molded products.
PART 02
Boluo polypropylene material solution empowers efficient application of IMC process
In response to the special requirements of IMC process, Boluo International has developed a series of specialized polypropylene material grades, such as HJ060UBC and BJ356AI.
These materials have the following advantages:
Excellent adaptability and dispersibility of long glass fibers;
Good fluidity enhances injection molding ability;
Support thinner wall design to enhance lightweight space;
Achieve an excellent balance between rigidity, strength, and impact performance.
The actual test results show that:
Under the same mold and testing location conditions, the performance of Boluo International PP+IMC process products can be basically consistent with traditional long fiber material injection molded parts.
(The above data comes from sampling tests on parts with the same mold and position)
PART 03
CAE simulation: Empowering IMC product development
In addition to material solutions, Boru International's CAE simulation technology team can provide systematic support in the early stages of projects, helping customers reduce development risks and shorten cycles.
Accurate modeling of material properties:
Prediction and correction based on Halpin Tsai model algorithm;
Combining the anisotropy of long fiber materials for secondary correction;
Simulate the orientation of injection molded fiberglass to provide more accurate material parameters.
Schematic representation of material anisotropy
Comprehensive structural and forming analysis:
For specific components, Boru International's CAE team can provide structural simulation analysis, including assembly force analysis, vibration durability analysis, thermal analysis, and fatigue life prediction. At the same time, the team can also conduct injection molding analysis on products in conjunction with mold design, including flow behavior analysis, pressure holding strategy optimization, warpage deformation prediction, and cooling efficiency optimization. Through simulation methods, risk points can be identified in advance, and design schemes can be optimized to ensure stable performance of the product under real working conditions.
Vibration Analysis of IMC Process Front end Framework
IMC Process Front end Framework Model Flow Analysis
PART 04
Application scenario: Accelerating the implementation of "replacing steel with plastic"
The PP+long glass fiber IMC process combines the four advantages of cost reduction, efficiency improvement, quality improvement, and low carbon, making it particularly suitable for lightweight applications of large structural components such as battery pack shells, bottom panels, luggage racks, front end frames, instrument panel frames, and seat structural components. Under the trend of new energy vehicles and lightweighting, IMC is becoming one of the key technological paths.
Conclusion
Through the deep integration of material innovation and CAE simulation, Boru International is continuously promoting the IMC process from "feasible" to "optimal".If you are interested in IMC related material performance data, product structure design, molds and molding processes, please feel free to contact us.The Boluo International Automotive Technology Team will provide you with comprehensive support to assist in the efficient implementation of the project.
