What is the difference between IML process and ordinary injection molding?

The IML process is significantly different from the ordinary injection molding process in many aspects. The following is a detailed analysis of these two processes:

1. Process principle

The ordinary injection molding process is a molding process in which molten plastic is injected into a mold and then cooled and solidified to form a plastic product of the desired shape and size. It mainly relies on the high-temperature fluidity of plastic and the cooling effect of the mold to achieve product molding.

The IML (In-Mold Labeling) process, that is, the in-mold labeling process, is a molding process that puts the printed film label into the mold and then injects plastic to tightly combine with the label. The key to the IML process is the tight bond between the film label and the plastic, as well as the stability and positioning accuracy of the label during the molding process.

2. Material selection

Ordinary injection molding processes mainly use various thermoplastics, such as polyethylene, polypropylene, polyvinyl chloride, etc. These plastics have good fluidity, formability and mechanical properties and are suitable for manufacturing various plastic products with simple structures.

The IML process requires the use of film materials with special properties as labels, such as polyester film, polyamide film, etc. These film materials offer good printability, heat resistance, chemical resistance and mechanical strength to ensure stability and tight bonding with the plastic during the injection molding process.

3. Molding process

The molding process of ordinary injection molding process is relatively simple, mainly including the steps of plastic melting, injection into the mold, cooling and solidification, and demoulding. In this process, parameters such as mold temperature, pressure and time have an important impact on the quality and molding effect of the product.

The molding process of the IML process is relatively complicated. It is necessary to put the film label into the mold before injection molding and ensure that its position is accurate and stable. Then, the molten plastic is injected into the mold through the injection system of the injection molding machine, so that the plastic and the label are tightly combined. During the injection molding process, parameters such as temperature, pressure and time need to be strictly controlled to ensure the tight combination between the label and the plastic and the molding quality of the product.

4. Product features

Products manufactured by ordinary injection molding processes have the characteristics of simple structure, stable dimensions, and good mechanical properties, but the surface decoration effect is relatively limited.

Products manufactured by the IML process have the advantages of rich surface decoration effects, integration of labels and products, wear resistance, scratch resistance, and chemical corrosion resistance. Since the label is closely combined with the plastic, the label is less likely to fall off or be damaged during use, improving the durability and aesthetics of the product.

5. Application areas

Ordinary injection molding processes are widely used in the production of various plastic products, such as home appliance casings, auto parts, packaging containers, etc.

The IML process is more suitable for the production of products that require rich surface decoration effects and high durability, such as home appliance panels, mobile phone casings, automotive interior parts, etc. In these fields, IML technology can provide unique visual effects and high-quality product performance to meet consumers' needs for product appearance and quality.

To sum up, there are significant differences between the IML process and the ordinary injection molding process in terms of principles, material selection, molding process, product characteristics and application fields. The IML process plays an important role in the production of high-end plastic products with its unique decorative effects and durability advantages. As consumers continue to improve their requirements for product appearance and quality, the application prospects of the IML process will become broader.