The fabric insert injection molding approach can be applied to produce easily recyclable self-reinforced polymer composites (SrCs) whose reinforcement and matrix are from the same polymer. However, the mechanical properties of the SrCs are usually limited due to the poor impregnation of the inserted fabric. In this work, the ultra-high molecular weight polyethylene (UHMWPE) fabrics were used as the insert, and the high-density polyethylene (HDPE) melt was injected to fill the mold cavity and impregnate the fabrics. The UHMWPE/HDPE two-component SrCs were prepared. The large difference of melting temperatures between UHMWPE and HDPE can establish a wide processing temperature window, and thus the impregnation of the fabric can be improved by increasing temperature. The tensile strength and modulus of the UHMWPE/HDPE SrCs were up to 148 and 1132 MPa, respectively. The peel strength could be up to 35.2 N/cm. The influences of four main injection molding parameters, including the injection temperature, injection pressure/packing pressure, injection velocity, and packing time, were investigated. The temperature, pressure, viscosity, and density of the matrix in the mold cavity were calculated by the numerical simulation to indicate the impregnation process during the fabric insert injection molding process.
Keywords: injection molding; mechanical properties; polyethylene; processing parameter; self-reinforced composite.