Thermoset, or thermosetting, plastics are synthetic materials

that strengthen during being heated, but cannot be successfully

remolded or reheated after their initial heat-forming. This is in contrast
to thermoplastics, which soften when heated and harden and
strengthen after cooling. Thermoplastics can be heated, shaped and
cooled as often as necessary without causing a chemical change,
while thermosetting plastics will burn when heated after the initial
molding

Thermosetting plastics can only be heated and shaped once. If

re-heated they cannot soften as polymer chains are interlinked.
Separate polymers are joined in order to form a huge polymer. The
main thermosetting plastics are epoxy resin, melamine formaldehyde,
polyester resin and urea formaldehyde.

Thermosetting plastics, however, have a number of

advantages. Unlike thermoplastics, they retain their strength and
shape even when heated. This makes thermosetting plastics well-
suited to the production of permanent components and large, solid
shapes. Additionally, these components have excellent strength
attributes (although they are brittle), and will not become weaker
when the temperature increases.
 The first commercial thermoset plastic was developed by Dr. Leo
Baekeland in 1909.
It was a phenolic material trade named Bakelite. This thermoset material
offered the new benefit of being firmly set -- not changing its shape, even
under heat and pressure.
Bakelite was used extensively as an insulating material for handles on
cookware and irons, and later found its way into applications such as
telephone earpieces, electrical housings and connecting blocks. It was also
a key ingredient in many of the weapons used in World War II.

In 1872, experiments with phenolic resin had actually preceded

Baekeland’s work, beginning the work of German Chemist Adolf von
Baeyer, but these trials had succeeded only in producing viscous liquids or
brittle solids of no apparent value. It was Baekeland who succeeded in
controlling the phenol-formaldehyde condensation reaction to produce the
synthetic resin.

In 1907, Bakelite, trademarked synthetic resin invented by Belgian-born

chemist Leo Hendrik Baekeland. The beginning of the modern plastics
industry is often dated to Baekeland’s first patent application
 In 1909, Baekeland made the first public announcement of his invention,
in a lecture before the New York section of the American Chemical Society.
In 1910, Baekeland had a semi commercial production operation
established in his laboratory and began operation in Perth Amboy on 1911.

In 1920’s, it was widely used in knobs, dials, circuitry panels, and even
cabinets for radios, and it was also employed in the electric systems of
automobiles. In 1927, Bakelite patent expired.

In 1930’s, cast Bakelite, along with many other competing phenolic

resins, enjoyed a vogue in colorful costume jewelry and novelties. Bakelite
faced competition from other thermosetting resin such as urea
formaldehyde and melamine formaldehyde and new thermoplastic resin.
 Phenol formaldehyde resins (PF) or phenolic resins are synthetic
polymers obtained by the reaction of phenol or substituted phenol with
formaldehyde. Used as the basis for Bakelite, PFs were the first
commercial synthetic resins (plastics).They were at one time the primary
material used for the production of circuit boards but have been largely
replaced with epoxy resins and fiberglass cloth, as with fire-resistant FR-4
circuit board materials

The phenolic resin’s polarisability is 10-24cm3 and Enthalpy

of vaporization is 43.52 kJ/mol.72.5 °C is it‘s flash point, 181.8 °C at 760
mmHg it’s boiling point and 0.614 mmHg at 25°C is it’s vapor pressure.

Phenolic resin has the colour is Resin itself tends to be amber-colored. It

has Wide variation depending on fillers and nature of resin. Usually it
seems hard and rigid, with good dimensional stability. It may be brittle in
thin sections with low impact strength. It is very easy to mould. It is Smooth
and has lustrous surface. Phenolic resin has retain properties at freezing
temperatures.

The phenol formaldehyde have Improved strength and dimensional

stability and Improved impact resistance and also cast resins.
Phenol formaldehyde wide range of molding powders is available in which
the composition of the resin, fillers etc. is varied to provide mouldings
suitable for many purposes.

It is good dimensional stability on heating up to about 300 degree F

Poor conductors of heat , so that handles of pans etc stay cool to touch. It
can burn only with difficulty. It is good electrical insulators, Laminated
Plastics.

Billiard balls, Accessories, Refractory, Laboratory countertops.

 Urea-formaldehyde, also known as urea-methanal, so named for its
common synthesis pathway and overall structure, is a non-transparent
thermosetting resin or plastic. It is produced from urea and formaldehyde.
These resins are used in adhesives, finishes, particle board, MDF, and
molded objects. UF and related amino resins are a class of thermosetting
resins of which urea-formaldehyde resins make up 80% produced globally.
Examples of amino resins use include in automobile tires to improve the
bonding of rubber to tire cord, in paper for improving tear strength, in
molding electrical devices, jar caps, etc.

Urea-formaldehyde resin's attributes include high tensile strength,

flexural modulus, and a high heat distortion temperature, low water
absorption, mould shrinkage, high surface hardness, elongation at break,
and volume resistance. Index of Refraction = 1.55. It is stiff, hard, strong,
brittle, good electrical insulator.

Fuse, Kitchen Wares, Toilet Bowls, Switch

 An alkyd is a polyester modified by the addition of fatty acids and
other components. They are derived from polyols and a dicarboxylic acid or
carboxylic acid anhydride. The term alkyd is a modification of the original
name "alcid", reflecting the fact that they are derived from alcohol and
organic acids. The inclusion of the fatty acid confers a tendency to form
flexible coating. Alkyds are used in paints and in moulds for casting. They
are the dominant resin or "binder" in most commercial "oil-based" coatings.
The original alkyds were compounds of glycerol and phthalic acid sold
under the name Glyptal.

Good weathering properties and are important ingredients in many

synthetic paints due to their versatility and low cost.

One of the important attributes of alkyd resins is their good

compatibility with many other coating polymers

Very long emulsified oil-drying alkyds are also added to synthetic

latex house paints to improve adhesion to chalky painted surfaces,
whereas medium to short oil alkyd resins are sometimes blended with
silicone resins with high phenyl content for air-dried or baked coatings to
improve heat or weather resistance

Coating Products
 A polyamide is a macromolecule with repeating units linked by amide
bonds.

Polyamides occur both naturally and artificially. Examples of naturally

occurring polyamides are proteins, such as wool and silk. Artificially made
polyamides can be made through step-growth polymerization or solid-
phase synthesis yielding materials such as nylons, aramids, and sodium
poly(aspartate). Synthetic polyamides are commonly used in textiles,
automotive applications, carpets and sportswear due to their high durability
and strength. The transportation manufacturing industry is the major
consumer, accounting for 35% of polyamide (PA) consumption

Polyamides (PAs) are produced either by the reaction of a diacid with a

diamine or by ring-opening polymerization of lactams. They are either all
aliphatic or all aromatic.

The aromatic polyamides, often called aramids, have higher strength,

better solvent, flame and heat resistance and greater dimensional stability
than the all aliphatic amides but are much more expensive and more
difficult to produce.

Poly(p-phenylene terephthalamide) & Poly(m-phenylene isophthalamide)

High melting points. Ultra high tensile strength at low weight, and
excellent flame and heat resistance.

Flexible Conduits, Ropes, Kitchen Wares, Gears, Ties

 Unsaturated polyesters are condensation polymers formed by the
reaction of polyols (also known as polyhydric alcohols), organic compounds
with multiple alcohol or hydroxy functional groups, with saturated or
unsaturated dibasic acids. Typical polyols used are glycols such as
ethylene glycol; acids used are phthalic acid and maleic acid. Water, a by-
product of esterification reactions, is continuously removed, driving the
reaction to completion. The use of unsaturated polyesters and additives
such as styrene lowers the viscosity of the resin. The initially liquid resin is
converted to a solid by cross-linking chains.

The properties of the cross-linked unsaturated polyester resins depend

on the types of acids and glycols used and their relative proportions.

Unsaturated polyester resins form highly durable structures and coatings

when they are cross-linked with a vinyl reactive monomer, most commonly
styrene.Their low cost, ease of use and weight advantages make them
prime candidates for a wide variety of structural and decorative
applications.

Unsaturated polyester resins also have excellent service temperatures.

They have good freeze-thaw resistance and can be designed for use in
many low to moderate temperature applications ranging from refrigerated
enclosures to hot water geysers.
 Unsaturated polyester resins are further classified into the following
categories:

• Ortho-phthalic polyesters – resins made from ortho-phthalic

anhydride are generally cheaper than the other two classes of
unsaturated polyester resins. They are usually used to manufacture
general purpose composite laminates where only moderate structural
properties are required.

• Iso-phthalic polyesters – resins made from Iso-phthalic acid. These

resins are much more structurally competent than the ortho-phthalic
resins. They also have superior corrosion resistance and are used for
more demanding applications

• Tere-phthalic polyesters – Tere-phthalate resins are made from tere-

phthalic acid. These resins are currently made in small volumes and
are considered a specialty resin. Although they tend to have better
thermal and chemical resistance than iso-phthalic resins they are
difficult to manufacture.

Livelihood Products
 Polyurethane (PUR and PU) is a polymer composed of organic units
joined by carbamate (urethane) links. While most polyurethanes are
thermosetting polymers that do not melt when heated, thermoplastic
polyurethanes are also available.

Polyurethane polymers are traditionally and most commonly formed by

reacting a di- or polyisocyanate with a polyol. Both the isocyanates and
polyols used to make polyurethanes contain, on average, two or more
functional groups per molecule.

The diverse properties of castable polyurethane make it leading choice

of engineers lasting materials for their high load, high stress environment.

Polyurethane routinely outperforms rubber and steel in its overall ability

to resist harsh environmental factors such as abrasion, heat, solvents, oil
and acid. Polyurethanes noise abatement ability makes it the preferred
material in chain-drive designs, conveyor belt systems anad assembly line
environments. Polyurethane’s incredible durability actually increases your
company’s profitability.

Polyurethanes are used in the manufacture of high-resilience foam

seating, rigid foam insulation panels, microcellular foam seals and gaskets,
durable elastomeric wheels and tires (such as roller
coaster, escalator, shopping cart, elevator, and skateboard wheels),
automotive suspension bushings, electrical potting compounds, high
performanceadhesives, surface coatings and surface sealants, synthetic
fibers (e.g., Spandex), carpet underlay, hard-plastic parts (e.g., for
electronic instruments), condoms, and hoses
 Melamine is an organic base and a trimer of cyanamide, with a 1,3,5-
triazine skeleton. Like cyanamide, it contains 67% nitrogen by mass and, if
mixed with resins, has fire retardant properties due to its release of nitrogen
gas when burned or charred, and has several other industrial uses.
Melamine is also a metabolite of cyromazine, a pesticide. It is formed in the
body of mammals that have ingested cyromazine. It has been reported that
cyromazine can also be converted to melamine in plants.

Stiff, hard, brittle unless laminated, good electrical insulator, resists

chemicals well, strong, resists some chemicals and stains. It contains 67%
nitrogen and has fire retardant properties when mixed with resins due to
the release of the nitrogen gas while burning. Melamine can also be used
as a pesticide. It forms a major component in pigment yellow 150, which is
a colorant in plastics and inks, melamine is also used as a super plasticizer
to make high resistant concrete.

Sulfonated melamine formaldehyde is used as a cement admixture to

increase the fluidity and workability of the mixture while reducing the water
content in the mixture during its handling and pouring. It results in a
concrete with higher mechanical strength and a lower porosity, exhibiting a
longer lifetime and an improved resistance to corrosive environments.
Melamine is also used as a fertilizer due to its high nitrogen contents;
however, it is much costlier to produce than other nitrogen fertilizers like
urea. Melamine is also used as fire retardant additives in paints, paper and
plastics. Melamine is sometimes added to food products to illegally
increase the apparent protein content.

Plates, mugs and etc.

 Silicones, also known as polysiloxanes, are polymers that include any
inert, synthetic compound made up of repeating units of siloxane, which is
a chain of alternating silicon atoms and oxygen atoms, frequently combined
with carbon and/or hydrogen. They are typically heat-resistant and rubber-
like, and are used in sealants, adhesives, lubricants, medicine, cooking
utensils, and thermal and electrical insulation. Some common forms include
silicone oil, silicone grease, silicone rubber, silicone resin, and silicone
caulk.

Long bond length combined with a wide bond angle and a low barrier to
rotation give polydimethylsiloxane (PDMS) outstanding flexibility, internal
mobility, and large free volume. Resists temperature extremes, weathering,
aging, oxidation, moisture, many chemicals, and ultraviolet radiation and is
generally non-irritating.

Silicones are highly permeable to oxygen, nitrogen, and water vapor

(but not to water molecules). Silicones have a very springy nature. You can
compress them, stretch them, bend them, smash them, and spread them
(over and over again), and they will simply bounce back with their
properties and volume intact.

Silicone Products.
 Epoxy resins are low molecular weight pre-polymers or high
molecular weight polymers which normally contain at least two epoxide
groups.

Epoxy Resins, also known as polyepoxides, are class of reactive

prepolymers and polymers which contain epoxide groups. Epoxy resins
may be reacted either with themselves through catalytic
homopolemerisation, or with a wide range of co-reactants including
polyfuntional amines, acids, phenols, alcohols, thiols.

The primary reason for epoxy’s popularity is its superb mechanical

strength. Welding is often the only alternative. Epoxy is nearly always
cheaper and faster than welding. Epoxy also has excellent resistance to
chemicals. After setting, there is no worry of a chemical reaction that will
weaken the seal.

It also resists heat. That resistance makes it ideal for electronics and
electrical systems and other industrial applications. Those who use epoxy
are aware of the superb mechanical strength and low curing contraction.
They also know the epoxy resins are well-balanced industrial materials and
suited to a broad range of applications. Its thermal and electrical properties,
strength, and durability are what epoxy is noted for. Those properties along
with the resistance to immersion and hostile chemical vapor are the reason
epoxy often is chosen by engineers.

Furnitures, Sculptures, Art Works

The Thermoset Plastic Manufacturing Process
Thermoset plastic industrial laminates are identified in process by three
stages: A, B and C.

A-stage refers to the key raw materials described earlier - reinforcing

substrates and resin binders.

B-stage refers to the product produced when reinforcing substrates and

resin binders are brought together but not fully cured. The reinforcing
substrate is unwound from a large master roll and dipped into a bath of
liquefied resin binder. The reinforcing substrate becomes either saturated,
as is the case with absorbent papers and cotton cloths, or coated, as is the
case with glass and graphite cloths. Once the wet resin binder is joined
with the reinforcing substrate in this method, it is slowly drawn through a
long conveyorized oven where the liquefied resin binder is dried (see
sketch below). The result leaves dry semi-cured resin bind in and/or on the
reinforcing substrate. Once joined and dried in this fashion, the product is
referred to as B-stage or prepreg, and the process described is called B-
staging, prepreging or treating.

C-stage refers to sheet, rod, tube, angle or other in their "cured stage".

 Sheets - B-stage is sheeted into plies then laid on top of each other
into predetermined stacks that will render a given thickness. These
stacks are placed into the hydraulic laminating press between two flat
surfaces and pressure is applied. While under pressure, heat is
introduced to begin the bake cycle. The resin in the B-stage product
is re-activated by the heat to a sticky state which moves slowly, filling
and bonding the layers together until it eventually hardens and
cures. Once plies bond to each other and cure, they are referred to
as C-stage laminate sheet and the process described is called
laminating or pressing.

 Rods - The B-stage is convolutely wrapped under tension onto itself,

 much like a roll of paper towels is wound. Once the B-stage is rolled
to form a rod, it is placed into a laminating press which has upper and
lower half round mold cavities. When the two half round molds close
and meet each other, a full round is formed. The size of the mold
cavity determines the diameter of the finished rod. Once pressure is
applied, the layers are pressed together filling all voids. Similar
pressures and heat cycles employed for making sheet are
used. When the layers bond to each other and cure, they are
referred to as C-stage laminate rod or rolled and molded rod.

 Tubes - Rolling tubes is nearly identical to rolling rods with the

exception that a steel rod called a mandrel is employed to size and
form the inside diameter of the tube. B-stage rolled tubes are usually
placed into an oven chamber as opposed to a press. Tube bake
cycles compare to those of sheet and rod. Once cured, the center
mandrel is extracted. The final cured product is referred to as C-
stage laminate tube or rolled tube.

 Angles - This process is nearly identical to that of sheets except the

mold cavities are "V" shaped rather than flat surfaces. The final
cured product is referred to as C-stage laminate angle or molded
angle.

 Other shapes - Once cured, the end product is referred to as C-

stage.

Prepared by:

Team 7

Gines, Aleza Rose L.

Baguio, Joycee Mae V.

Arcillas, Marilou O.

Ceballos, Renald C.

Caguioa, Dexler

Lahaylahay, Marvin
Names Properties Main Uses
Example
Product
Epoxy resin (Epoxide, Good electrical Casting and
ER) insulator, hard, encapsulation,
brittle unless adhesives,
reinforced, resists bonding of other
chemicals well. materials. Used for
printed circuit boards
(PCB’s) and surface
coatings.

Melamine Stiff, hard, strong, Laminates for work

formaldehyde resists some surfaces, electrical
(MF) chemicals and insulation, tableware.
stains.

Melamine Stiff, hard, brittle Casting and

formaldehyde unless laminated, encapsulation,
(MF) good electrical bonding of
insulator, resists other materials, car
chemicals well. bodies, boats.

Urea formaldehyde Stiff, hard, strong, Electrical fittings,

(UF) brittle, good handles
electrical insulator. and control knobs,
adhesives.

Phenol formaldehyde A colourless polymer Dark coloured

(PF, Bakelite) - coloured with electrical
artificial pigments to fittings and parts for
produce a wide domestic appliances,
range of different bottle tops, kettle
colours. handles, saucepan
handles.