Thermoplastic Overmolding onto Injection-Molded and In Situ Polymerization-Based Polyamides

We investigated products manufactured by in situ polymerization, which were reinforced with overmolded ribs. We developed our own mold and prototype product for the project. We used three different materials as preform: a material with a magnesium catalyst, manufactured by in situ polymerization, a Brüggemann AP-NYLON-based in situ polymerization material and an injection-molded PA6 (Durethan B30S, Lanxess GmbH) material. The ribs were formed from the same PA6 material (Durethan B30S, Lanxess GmbH). We examined the effect of the different technological parameters through the pull-off of the overmolded ribs. We measured the effect of melt temperature, holding pressure and holding time, and mold temperature. Considering the individual preforms, we pointed out that monomer migration and binding strength are related, which we concluded from the temperature-dependent mass loss of the materials, measured by thermogravimetric analysis (TGA). Finally, we designed a mold suitable for manufacturing overmolded parts. We designed and built pressure and temperature sensors into the mold to examine and analyze pressures and temperatures around the welding zone of the materials.