The use of IFGs can lead to melt-to-melt contact in an injection overmolding operation under normal conditions where there is no melting for flat interfaces. By promoting melting, IFGs results in improved adhesion for material combinations where adhesion mechanism is either interdif-fusion or chemical reaction. Thermal modeling allows the IFG to be optimized for a particular situation. For example, density of features, aspect ratio, tip angle, etc. can be easily simulated to determine the structure that is the best compromise between enabling melt-to-melt contact and manufacturability. With right knowledge of the materials and processing, over-molding conditions can be chosen to obtain good adhesion for a variety of applications.
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