INJECTION MOLDING OF THERMOSETS

The polymer molecules in thermoplatic materials are held together by electrostatic

forces. When the material is heated, these forces diminish and the plastic softens and
ultimately flows.

Thermosetting materials are held together by chemically cross-linking the

polymer molecules. The molded, cured parts are substantially infusible and insoluble.
They cannot be resoftened by heat.

# THERMOSETTING MOLDING MATERIALS

Thermosetting molding materials consist of thermosetting resins mixed with

fibers, lubricants, pigments etc. and a small quantities of catalysts to bring about the
chemical change of cross linking.
 The cured or cross-linked resin is insoluble and infusible and cannot be reground.
 The most frequently used resins are phenolics, polyesters, melamines, ureas, epoxy
and silicones.
 Thermosetting molding materials are characterized by their fillers. General-purpose
phenolics normally contain about 50 percent of wood flour and high impact materials
may contain fibrous organic fillers. Electrical grade contain glass fiber and heat-
resistant grades have asbestos or other mineral fillers.
 The fillers are included because in general, the resins are not strong enough to be used
alone and also to make the product cheaper. They increase the properties like impact
resistance, electrical properties, heat resistance, flexural strength, rigidity, toughness
etc.
 The behavior during molding of thermosetting molding materials is characterized in
two main ways
(1) cure time
(2) time of flow
 the cure time, determined by molding a standard item in a standard mold
at set conditions, is the time taken from the moment of complete closing of a
compression mold containing a charge of material to the time when cure is complete.
Three general grades of molding powder are produced being classed as fast, medium
and slow cure.
 The time of flow is determined in a standard beaker mold and is known as the cup
flow time. The required amount of the molding powder is placed in the standard cup
flow mold which is maintained at a set temperature. The mould is closed using a set
pressure, and the time taken from when the full pressure is first applied to the time
when flow of material in the mold ends. A free flowing material (or soft flow) may
take about 10 sec., medium flow 15 sec., and a stiff flow about 20 sec.
 It is possible to mold nearly all types of thermosetting molding powders by injection
techniques, but the best results are obtained with materials of soft to medium flow
and medium cure. Fast curing powders tends to set up before the mold is filled, while
slow curing powders take too long to mould.

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# MACHINES FOR THERMOSET PLASTICS

Some modifications are necessary to the standard injection molding machines to

make it suitable for the molding of thermoset plastics. The parts, which require special
attention, are as described below.

(a) Hopper

 The shape of the hopper should be such that there is a free flow of powder.
 The taper per side should be 150 to 200 and the volume of material in the hopper
should above half mark to insure a pressure on the material that will bring a constant
flow to the screw.

(b) Feed-throat

 Throat temperature should be maintained properly and maintained at midpoint

between room temperature and the rear zone setting of the cylinder.

( c ) Fluid heated barrel

 The heating cylinder or barrel is made of the same material as the thermoplastic
cylinder.
 The barrel in a thermoset machine is generally shorter than in a thermoplastic press of
a corresponding size.
 The barrel temperature should be maintained accurately to avoid premature curing.
 The higher temperature can be caused by higher back pressure, higher speed of screw,
or any cause that adds to the frictional heat.
 To stop this jackets are clamped around the barrel and a preheated fluid ( oil, water
etc. ) is circulated through jacket instead of using conventional band heaters.
 This initially raises the barrel to the required temperature and when requires removes
excess heat.
 Like the electrical heating, this type of temperature control is divided in zones, so that
the feed end can be at a different temperature from the center of the cylinder and from
the nozzle zone.
 Typical temperatures for urea formaldehyde would be 750c at the feed hopper,
increasing to 95-1000 c at the nozzle.
 80% of heat is provided by friction and exothermic chemical reaction. 20% of heat is
achieved during the melt’s passage through nozzle, runner and cavity.
.
(c) Screw

 Most screws for thermoset injection molding have a compression ratio 1:1 (zero
compression) i.e. constant channel depth throughout the length of the screw.
 L/D ratios are considerably smaller (12 to 15:1) because the three different screw
functions for thermoplastic molding are not required.

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 Smaller L/D ratios also ensures the low residence time of material.
 The screw does not have non-return valve at the screw tip.
 The tip of the screw matches the internal shape of the cylinder head for smooth flow
of the material. So that after injection there is a minimum amount left behind.
 Screw speed should be in the range of 50 to 100 rpm.
 The screw rotation should stop just at the time of mold opening. If the material is
permitted to lie in the cylinder for too many seconds prior to shooting time, the
preheated material can start curing.

(d) Nozzle

 The nozzle and the injection head are designed for quick removal in the event that the
thermosetting material sets up in the screw or nozzle.
 This problem can be overcome by specially designed nozzle material and improved
technique.
 The nozzle temperature should be such that while contacting the mold, it will not get
hot enough to cause cure of material.
 A water jacket with controlled coolant flow or sprue-break is required to avoid cure
of material.
 Sprue-break allows a period when the nozzle can cool off after the injection and cure
time, and when the machine is running smoothly with effective sprue break it is found
that the nozzle will stay at a fairly steady temperature.

# MOLDS FOR THERMOSETS

 The molds for thermosets are similar to those for thermoplastics. The basic difference
is that thermosetting materials require hot molds to heat the material to initiate the
reaction while thermoplastic molds require cooling channels to remove the heat.
 The heaters are normally calculated to bring the mold to proper temperature in 1 hr or
less.
 The mold must be hot enough to cure the resin rapidly, but, at the same time, it must
allow the resin to completely fill the mold prior to start of curing. So that mold
temperature control should be within +/- 50 C. Typical mold temperature are :

Material Temperature ( 0 C )
Urea 146-154
Melamine 154-171
Diallyl phalate 166-177
Epoxy 177-188
Phenolic 177-199

 The mold should be insulated from the platen to prevent heat transfer. Asbestos filled
fibers are used for this purpose.
 Electrical heaters are generally used for mold heating.

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 If the mold temperature is lower than the curing time then curing time will be longer
resulting in longer cycle time and hence lower productivity.
 Gates and runners are similar to those in use for injection molding of thermoplastics.
The same type of gating can be used, including restricted and submarine gates. Full
round runners are much more important with thermosets. Runners and gate should be
polished.

# INJECTION MOLDING OF THERMOSETS – PROCESS

The complete injection molding process of thermosets is as follows :

 The material is fed in to the hopper (normally in granular form) and from there it
drops onto a screw.
 To prevent premature heating of the material near the feed pocket of the machine (or
even in the feed hopper), it is wise to cool the rear portion of the cylinder.
 The screw brings the material into its heated housing or cylinder. The cylinder is
carefully maintained at a temperature of between 75-80 0 C and 1200 C according to
the type of material.
 The screw is driven by a suitable power source, and, while moving the material
forward, heat is absorbed from the cylinder and from the frictional work of the screw.
 As the heated material works its way to the tip of the screw, it brings about a
backward movement of the screw. For a distance that provides enough material for
the shot at the front of the cylinder.
 At this point, screw rotation stops, and a hydraulic cylinder forces the screw forward.
This move injects the plastic into the mold through the nozzle, which is in close
contact with the mold.
 In the mold, the material passes through the sprue bushing, runners, and gates and
into the cavities.
 The heated mold supplies the necessary energy for cure; upon completion of the
hardening process, the mold opens and parts are ejected.
 Upon completion of the injection-hold time, the cylinder retracts to break contact
with the mold and starts preparation of the material for next shot.
 Upon ejection of the parts, the mold halves have any loose flash blown off.
 Following this, the mold closes and the next cycle starts.

# PROCESS VARIABLES

The main factors affecting the temperature of the melt in the cylinder are the
barrel temperature, screw speed, back pressure and mold temperature.

(a) Barrel Temperature

 If the barrel temperature is too low the plastic will remain granular and not start to
flux.
 If it is too high it will permit the material to overheat and pressure.

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(b) Screw Speed

 Screw speeds for thermoset moldings are in the area of 50 rpm. It has a direct effect
on the material temperature.
 If too fast screw speed, the screw will retract too quickly and not give sufficient time
for adequate heat transfer from the barrel.

( c )Back Pressure

 Excessive back pressure can cause compression of the material over a longer distance
of the screw flights, making the injection more difficult.
 The back pressure contributes to temperature rise of the material due to added work
input.
 When filled with higher pressure, the material in the measuring chamber is denser,
making shot larger.

(d) Mold Temperature

 A short molding cycle is favored by a high mold temperature, but if too rapid curing
takes place the moldings are liable to exhibit porosity in the thicker sections and some
burning may take place. Flow marks, warping and excessive shrinkage may occur
with too rapid curing. So the mold temperature should be optimum.

# ADVANTAGES OF INJECTION MOLDING OF THERMOSETS

(1) The product display properties superior than those produced with thermoplastics.
(2) Product posses superior heat and chemical resistance, they are rigid, their
resistance to creep is better than glass-filled thermoplastics.
(3) Product cost can be reduced by use of fillers.
(4) No cooling channels are required in the mold.
(5) Shorter barrel is required in this process.
(6) The heat load requirements are lower than thermoplastic molding.
(7) For high volume production, injection molding of thermosets is advantageous.

# DISADVANTAGES OF INJECTION MOLDING OF THERMOSETS

(1) The waste material can not be recycled.

(2) Mould heating arrangements are required in this process.
(3) The mould requires to be insulated to prevent heat loss.
(4) Precise temperature control of barrel is required to prevent premature curing of
material.
(5) After processing the barrel must be cleaned cured material remaining in it may
cause problem during next processing.

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 (6) The costs of auxiliary equipments are much higher.
# DIFFERENCE BETWEEN INJECTION MOLDING OF THERMOPLASTICS
AND THERMOSETS
INJECTION MOLDING OF
THERMOPLASTICS
 In the thermoplastic press, the screw has
functions of both heating and conveying
the resin
 Compression ratio in the screw is
generally kept greater than 1. (i.e.
different channel depth in diff. zones)
 The thermoplastic screw has non-return
valve at the screw tip
 L/D ratio of thermoplastic screw is higher
than that of thermoset screw
 The barrel temperature on a thermoplastic
press can run as high as 3150 C
 Conventional electric heaters are used for
heating barrel
 The barrel length in a thermoplastic press
is generally greater than in a thermoset
press
 In thermoplastic molding process, hot
resin is injected into a cold mold.
 The mold is not generally insulated
 The waste material (gate, runner) can be
recycled
 Upon cooling the polymer molecules are
held together by electrostatic forces
 PP, PE, ABS, PS, PC, Poly Acetal, PVC
are generally processed by this method
# REFERENCES :
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INJECTION MOLDING OF
THERMOSETS
 In thermoset press, the screw is
used mainly to convey the resin to the
nozzle.
 The compression ratio is kept 1.
(i.e. constant channel depth)
 The thermoset screw does not have
non-return valve at the screw tip
 L/D ratio of thermoset screw is
generally kept lower to ensure lower
residence time
 The barrel temperature on a
thermoset press can run in the range of
65-1750 C
 Fluid circulating jackets are used
for heating barrel
 The barrel length in a thermoplastic
press is generally greater than in a
thermoset press
 In thermoset process, warm resin is
injected into a hotter mold.
 The mold is generally insulated to
prevent heat transfer
 The waste material can not be
recycled
 Upon curing the polymer molecules
are held together by chemical cross-
linking
 The most frequently used resins are
phenolics, polyesters, melamines, epoxy
and silicones.
(1) Injection Molding of Plastic Components – John Bown
(2) Injection Molds and Molding – Joseph Dym
(3) Plastics Materials and Processes – Goodman
(4) Injection Molding – Rubin
(5) Injection Molding Machines - Whelan

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