In this study, the melt-flow behavior inside the sprue during the ultra-high-speed filling process of PP and GF-LCP was clarified using a modified glass-inserted mold. In particular, with the GF-LCP, melt-flow behavior within 3 ms was observed clearly and models of residual gas trapped in the resin were proposed in detail. The following results were obtained.
1) With the PP, the melt-flow behavior did not change at any injection rate in the range of 24.1 cm
3/s to 804 cm
3/s.
2) With the GF-LCP, jetting was generated at all injection rates and the jetted resin folded while filling by resin newly flowing in from the nozzle when the injection rate was less than 241 cm
3/s.
3) When the injection rate was higher than 482 cm
3/s with the GF-LCP, the jetted resin reached the sprue-end while maintaining a wave-form pattern and then filled back to the nozzle side while increasing the contact area with the cavity and glass surface from the sprue-end, without folding phenomenon.
4) At this time, V-notch shape resins were found to generate and disappear intermittently between the jetted resin and resin filling into its periphery. Based on these results, the mechanism of residual gas in the V-notch area trapping resins in was proposed in detail.
5) With the GF-LCP, resin pressure at the nozzle was reduced due to the jetting phenomenon, and temperature of the jetting resin gradually increased.
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