Hi-P IML Design Guide Line

Hi-PConfidentialInternational11Electro-MechanicsSolutionProviderIntegratedAnHi-PIMLDesignGuideLineHi-PConfidentialInternational2–OriginatingDept:AdvancedEngineering–Author:QiaoFenghua–Site:Shanghai,China–Changehistory:–IssueDateHandledByComments2009.12.15QiaoFenghuaInitialDraftCoverPageHi-PConfidentialInternational3Contents–ProcessDescription–PartDesignGuide–InjectionMoldingpartgating–Labeltopartalignment–Graphicalignmentanddesign–Colorsandprinting–GraphicDesignguide–LeatherIMLguide–Filmselection–InkselectionHi-PConfidentialInternational4Printingoffilm3DformingofthefilmTrimmingtheinsertInjectionmouldingPrintingmethodsinclude:•Screen•CMYKEachtypewillrequiredifferentprotectionfromeitherthemouldedplasticorabrasionFormingmethodsinclude:•Highpressure•Vacuum/thermo•MatchedmetalwarmembossingEachformingmethodhasadvantagesanddisadvantagesTrimmingmethods:•2Dbladeandblock•3Dcontouredmatchedmetal•Multi-axis/bladeTrimmingtoolsrequiresharpeningatregularintervalsInjectionmouldingisrelativelythesame,maindifferenceswillbehowthelabelisheldinthetool.ProcessDescriptionHi-PConfidentialInternational5Notes•Changesinthicknessshouldbegradualorsinkmarkswillbecreated.•Thicknesscanbethinnerinsmallareas,dependingongatelocation.RecommendedMin/MaxA3.0~5.0°Min.1.5°D0.5~1.0mmMin.0.3mmG0.05~0.20mmMax.0.3mmR0.5~1.0mmMin.0.3mmT1.2~2.0mmMin.1.0mmSplitline&AperturesTRTDAGFilmHi-PConfidentialInternational6AperturesandholesNotes•AnysmallerandthecuttingtoolisweakRecommendedMin/Max∅1.5~2.0mmMin.1.2mm*H1.8~2.0mmMin.1.5mmRa0.5~3.0mmMin.0.3mmS1.5~2.0mmMin.1.2mm*s∅RaHHHi-PConfidentialInternational7DepthandOuterRadiiNotes•Proportionofdepthtowidth/lengthshouldbeminimum1:5.Seegraphicregistration.•HMax.12mmHeightRtRcH≦7mm≧1.5mm≧3.0mm7H10mm≧2.0mm≧4.0mmH10mm≧3.0mm≧5.0mmAe5.0~10.0°Min.3.0°RcRtHRtAeHi-PConfidentialInternational8InternalMechanicalFeaturesNotes•‘N’:Smoothchangesofwallthicknesswillreducesinkmarks.MaterialshouldflowfromthicksectiontothinsectionsRecommendedMax.Tr≦Tx1/2=Tx2/3TrTNTrFilmHi-PConfidentialInternational9Gating1/2GateTypeNotesAHottipRequiresinverteddometoallowfor0.3mmwitnessmark.BHottip/valvegateontocoldrunnerswithtabgates.GivesgoodflowofpolymerbutrequiresthegatesystemtoberemovedasadditionalprocessABBAA-coverfrontHi-PConfidentialInternational10Gating2/2GateTypeNotesCHottipNeedsdomefeaturetoreduceeffectofheatandpressureDValvegateBiggerdiameterreducespressureESub/Tunnel/winklegateAllowsstandardtoolsetupandrelativelylowpressureontoribfeatureCDEA-coverbackHi-PConfidentialInternational11Graphictopartalignment1/2NotesAGraphicsinflatareaswithnoaperturesaremucheasiertoalignwithapositionaltoleranceof+/-0.2-0.8mm.BGraphicsonthe‘top’surfacebutneartheedgeradiiaremoredifficulttocontrol.Long,linearlinesshouldbeavoided.CGraphicsnearthecornersareverydifficulttocontrolastheyarestretchedin3directions.DThissideviewshowsthestretchingdownthesideofthepartthateffectsthegraphicsonthe‘top’neartheedge.CBExampleProblemgraphicsDAHi-PConfidentialInternational12Graphictopartalignment2/2NotesADramaticdeformationofthegraphicscanbeseenastheyarepulledoverthecorners.Predictinghowtheseareaswillvaryinproductionisverydifficult.BLinesgoingdowntheendoftheB-coverarenotstraight.ThismakesalignmentverydifficultwithamatchingA-cover.CSolutionistochangethegraphicssotheystopshortofendradiiABCExampleProblemgraphicsSolutionHi-PConfidentialInternational13ColoursandPrintingNotes•MostIMLin-boxcoversaredecoratedbythescreenprintingprocess.Thisgivesexcellentblockcolors,andallowsmetallicinkstobeused.Itisnotsuitableforphotographictypedecoration.•Lithographic/Gavier/CMYKprintingprocesscreatescolorsbyoverlayingsmalldotsofinktocreatephotolikedecoration.Thisisidealforgradientsfromonecolortoanother.ScreenprintedCMYKprintedHi-PConfidentialInternational14GraphicsDesignGuide1/3NOTRecommendedALonglinearlinesattheedgesaredifficulttocontrolAAligningdesigngroovestographiclinesthatareattheedgeofpartisdifficultBAligninggraphicstomechanicalfeaturesissometimesachallengebuteasierinthecentralareaofthetopsurfaceBAperturescansometimespullthegraphicsoutofshapeCGraphicswillbendinwardsattheendsmakingalignmenttostraightgroovesormatchingassembledpartsdifficultBABCHi-PConfidentialInternational15GraphicsDesignGuide2/3RecommendedAIfgraphicsneedtogoovertothesidesofthepartthentheyshouldbeasneartothecentreaspossibletoreducedistortion.BLineargraphicsshouldbekeptawayfromedgeorcornerradiitoreducedistortionCCompromisingthedesignalittlecanimproveyieldbyreducingfailurescausedbybadgraphicsalignmentwhenassembled.DTrytoavoidaligninggraphicswithapertureastheyareoftendistortedaroundtheseareas.ABBCAHi-PConfidentialInternational16GraphicsDesignGuide3/3ScreenPrintingGraphicguideAThewidthofline≥0.25mmorcan’tprintclearlineBThediameterofdot≥0.25mmorcan’tprintclearly.CDistancebetweenlogoandgraphics≥0.3mmCABHi-PConfidentialInternational17LeatherIMLGuide1/3aaa-aHaHbLeatherIMLguideAThicknessrangeofleatherfilm:0.4~1.0mmHaTheleatheristhickthanplasticfilm,tohaveagoodedge,weusealiptoovertheedgeoftheleather.Lip:0.5~0.8mmHb0.6~0.8mmAOneShotLeatherIML