The pursuit of mechanical strength in the injection molding of long-fiber-reinforced resins continues to pose major challenges, namely (1) improvement of fiber defibration and fiber distribution and (2) suppression of fiber breakage during the molding machine's plastication process. In the present study, a new defibration and distribution evaluation mold is developed to quantitatively evaluate the defibration and distribution of long fibers in nozzle-injected resin. A quantitative analysis method using this evaluation mold is proposed for visualizing and observing long-glass-fiber-reinforced resin up to 30 wt % and long carbon fiber-reinforced resin up to 10 wt %. The method, based on the intensity of light transmitted from a backlight source, is also used to evaluate areas of undefibrated fiber pilling and for evaluating the influence of molding conditions on fiber defibration and uniform distribution. The results clarify that fiber distribution non-uniformity can be reduced by improving the concentration adjustment procedure for the dry blending of high-concentration pellets. Additional results show that fiber defibration and distributive uniformity can be improved by applying high back pressure.
Keywords: distribution; injection molding; long-fiber-reinforced resins; plastication.