Prepreg Release Film Has Bulges

2024-09-06 by Cherry

The relationship between the bulge of the prepreg release

film has bulges and the die-casting machine

In the die-casting process, the use of prepreg release 

film is crucial. The role of the release film is to 

ensure that the molded metal parts can be easily separated

from the mold without any defects. 

However, in recent years, many manufacturers have found

bulges on the film surface when using prepreg release

film. These bulges not only affect the release effect, 

but may also have a certain impact on the performance 

of the die-casting machine. 

This article will explore in depth the causes of the 

bulge problem of the prepreg release film, its relationship 

with the die-casting machine,and how to effectively solve 

this problem.

What is a prepreg release film?

Prepreg release film is a special film material, which

is a film that plays a protective role during the preparation

and storage of prepregs. It can prevent the prepreg from 

sticking and facilitate subsequent processing and use.

Generally, the prepreg release film should have a smooth

surface, good demoulding performance and a certain strength.

Prepreg release film is widely used in the production process 

of composite materials. Its main function is to prevent the 

material in the die-casting mold from adhering to the mold 

surface. 

Due to its special properties, it is widely used in high-precision

manufacturing in industries such as aviation, automobiles, 

and electronics. In the die-casting process, release film can 

effectively extend the life of the mold and improve the 

surface quality of the parts.

Problem of bulges on prepreg release film

The phenomenon of bulges on the release film means that the

surface of the film is no longer flat, but small protrusions

or ridges appear. These protrusions will affect the uniformity

of the material, causing defects on the surface of the final 

product, and even causing the parts to be unable to be separated 

smoothly from the mold.

There are many reasons for the bulges on the prepreg release film,

mainly including the following aspects:

1. Changes in environmental humidity and temperature: The prepreg 

release film is very sensitive to the environment. When the

humidity or temperature is unstable, the film is easy to

deform and produce irregular bulges.

2. Improper material storage: If the release film is stored

in an inappropriate environment or exposed to high temperature

and high humidity for a long time, the performance of the 

material will be affected, resulting in bulges.

3. Uneven film thickness: Some low-quality release films 

have uneven thickness problems during the manufacturing 

process, which will cause irregular bulges on the surface

of the film in actual applications.

The relationship between die-casting machine and release

film protrusions

During the operation of the die-casting machine, the quality

of the release film directly affects the molding quality 

of the parts. When protrusions appear on the surface of the 

release film, the die-casting machine cannot maintain the

precise shape of the parts, thus affecting the overall quality

of the product.

1. The mold is not closed tightly: the die-casting machine

applies high pressure through the closure of the mold to

inject molten metal into the mold. When there are protrusions

on the prepreg release film, it will cause the mold to be 

closed loosely, which will affect the fluidity and filling

effect of the metal. As a result, the parts may have problems

such as uneven edges and rough surfaces.

2. The injection pressure is affected: the working principle

of the die-casting machine is to press the metal liquid 

into the mold through high pressure. If there are protrusions

on the release film, the injection pressure distribution

will be affected, and it will not act evenly on all 

parts of the mold, resulting in defects such as deformation 

and pores in the finished product.

3. Shortened mold life: The protrusions of the prepreg 

release film will increase the wear of the mold, especially

under high pressure conditions, the protruding part will

produce additional friction with the mold, over time,

this will cause surface damage to the mold and shorten 

its service life.

How to solve the problem of bulging of prepreg 

release film

There are many solutions to the bulging problem of prepreg 

release film. Here are some common and effective methods:

1. Control the production environment: Keep the temperature

and humidity of the production environment stable to avoid

the influence of extreme weather on the prepreg release film.

It is recommended to store the release film at a temperature

of 20℃~25℃ and keep the relative humidity below 50%. 

Strengthen quality control in the production process. 

During the preparation and processing of prepreg, pay attention 

to the operating specifications to avoid unnecessary damage 

to the release film. Check the surface quality of the release

film regularly to find and deal with bulges and other problems

in time.

2. Store the release film correctly: The release film should 

be protected from adverse environmental factors such as extrusion,

humidity and high temperature. It should be stored in a dry, 

ventilated and temperature-appropriate environment, and 

protected with appropriate packaging materials.

And avoid direct contact with sunlight. Long-term exposure 

to sunlight or high temperature environment will cause the 

film to bulge due to heat expansion. The release film should 

be placed in a suitable environment for reheating before use 

to ensure that the material is used in a stable state.

3. Choose high-quality release film: Try to choose prepreg 

release film with uniform thickness and stable quality. 

High-quality release film undergoes strict quality inspection

during the production process, and is not prone to uneven 

thickness or surface bulges.

4. Regularly check the die-casting machine and mold: Regularly

check and maintain the die-casting machine and mold to 

ensure that the equipment is in the best working condition. 

The operating status of the mold and die-casting machine has

a direct impact on the performance of the release film, and

any equipment problems may cause unnecessary bulges in the 

release film. Ensure that the die-casting machine is firmly

installed to reduce the transmission of vibration. 

The impact of vibration on the surrounding environment 

can be reduced by installing a shock absorber or adjusting

the position of the die-casting machine.

Control the operating temperature of the die-casting machine

to avoid the impact of heat radiation on the prepreg release film.

You can use insulation materials or adjust the distance between

the release film and the die-casting machine.

Best practices for preventing bulges

In addition to the above specific solutions, some best practices

can also be taken to prevent bulges in prepreg release films:

1. Before using the release film, make sure to check the surface

of the film to ensure that it is flat and intact. If any abnormalities

are found, it should be replaced in time.

2. Train the operators of the die-casting machine to ensure that 

they can correctly identify and deal with the problem of release

film protrusion to avoid affecting production efficiency.

3. Optimize the die-casting process parameters, especially the 

injection pressure and speed, to ensure that the metal liquid 

can evenly fill the mold without adding additional pressure to

the release film.

Conclusion

In short, the protrusion of the prepreg release film may be related

to the die-casting machine, but it may also be caused by many 

other factors. In actual production, we need to consider various

factors comprehensively and take effective measures to solve 

the problem of release film protrusion to ensure the quality

and performance of the prepreg.

At the same time, we should also continuously improve our

understanding of the composite material production process,

strengthen quality control and management, and contribute

to the development of the industry.

When solving the problem of protrusion of the prepreg release film,

we can also draw on some advanced technologies and experience. 

For example, new release film materials can be used, which may

have better anti-deformation and high temperature resistance. 

In addition, we can also reduce the impact of vibration and heat

on the release film by optimizing the production process.

Besides, it is also very important to communicate and 

cooperate with suppliers and peers. They may provide some valuable

suggestions and solutions to help us better solve the problem 

of bulges on prepreg release film.

The bulge problem of prepreg release film not only affects the 

quality of die-casting products, but may also have a negative 

impact on the working efficiency and mold life of the die-casting

machine. Therefore, during the production process, it is necessary

to strictly control environmental conditions, properly store the

release film, and regularly check the die-casting equipment.

By taking appropriate preventive measures, the bulge problem of 

the release film can be effectively avoided to ensure the smooth

progress of the production process.

In the future development, with the continuous advancement of 

composite material technology, we believe that the quality of

prepreg release film will be further improved. At the same time, 

we also look forward to the continuous optimization of the performance

of equipment such as die-casting machines to provide more stable

and reliable support for composite material production.

For more info, you can refer to: 

https://www.tiktok.com/@lk_diecastingmachine/video/7405113006880820522 

https://www.youtube.com/shorts/JLX410QV_kw

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