Co-injection molding:: Effect of processing on material distribution and mechanical properties of a sandwich molded plate

The effect of molding parameters on material distribution and mechanical properties of co-injection molded plates has been studied using experimental design. The plates were molded with a polyamide 6 (PA 6) as skin and a 20% glass fiber-reinforced polybutyleneterephtalate (PBTP) as core. Five molding parameters-injection velocity, mold temperature, skin and core temperature, and core content-were varied in two levels. The statistical analysis of the results showed that three parameters-injection velocity, core temperature, and core content-were the most significant in affecting skin/core distribution. A high core temperature was the most significant variable promoting a constant core thickness, while core content was the most significant factor influencing a breakthrough of the core. Mechanical properties, such as flexural and impact strength showed a high correlation with the skin/core distribution. The slight increase in falling weight impact strength of the sandwich molded plates, compared to similar plates molded from PBTP only, could be explained from the failure process, which initiates in the brittle core and propagates through the ductile skins.