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Thermoset sales slides

Thermoset sales slides






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    Thermoset sales slides Thermoset sales slides Presentation Transcript

    • Basics of Thermosets, Scientific Molding, and Steel Selection
    • Fundamental Differences between Thermoplastics and Thermosets
      • Thermoplastics are Supplied as Chemically Finished and Stable Compounds
      • Thermoplastics Must Be Melted and Converted at Relatively High Temperatures
      • Thermoplastics Can Be Repeatedly Softened and Solidified
      • The Bulk of Thermoplastic Materials Are Supplied As Unfilled Products Thermosets Are Supplied As Partially Formed Polymers
      • Processing Is Designed to Complete the Polymerization Process and Make the Molded Part At the Same Time
      • Conversion Temperatures Are Relatively Low
      • Finished Product Consists of a Network Solid That Cannot Be Re-melted
      • Almost All Thermoset Compounds Are Highly Filled
    • General Advantages of Thermosets
      • Low Initial Viscosity Allows for Long Flow Paths and Production of Large Parts
      • High Electrical Insulation Properties
      • Low Processing Temperatures Allow the Use of Organic and Thermally Unstable Fillers and Modifiers
        • Cotton Flock
        • Wood Flour
        • Polyester Fabric
        • Walnut Shells
        • Alumina Trihydrate (ATH)
        • Hemp
      • Good Cost/Performance Balance for Elevated Temperature Properties
      • Wide Range of Processes and Forms for Raw Material Provide Good Versatility in Design/Performance Equation
      • Cannot Melt or Soften in Catastrophic Thermal Runaway Events
      • High Levels of Filler Tend to Result in Materials That Shrink and Warp Less than Reinforced Thermoplastics
      • Excellent Compressive Properties
      • Batch Process Allows for Creative Material Modifications
      • More Creep Resistance Than Thermoplastic
    • General Disadvantages of Thermosets
      • Material Properties are Not as Developed as Thermoplastic
      • Low Initial Viscosity of Materials Results in Flash and the Need for Secondary Operations
      • Low Tensile Strength and Ductility Tend to Result in Parts Designed with Thick Walls
      • Compounds Are Reactive Systems – Results in Shelf Life Problems
      • Batch Processes Result in More Inconsistent Lot-to-Lot Consistency
      • High Levels of Some Fillers Result in Excessive Tool Wear
      • The Unique Nature of Each Thermoset Family Does Not Help Thermoset to Thermoset Replacements for Future Cost Reduction
      • Compound Formulations Overly Secretive
      • Some Material Suppliers Compete with Their Molding Customers
      • Product Quality Dependent Upon the Degree of Crosslinking Established During the Molding Cycle
      • Breakdown in High Vibration Applications
      • Poor Thermal Conductivity for Housing Replacements
    • Generic Specific Gravity Material Value Magnesium 1.74 Aluminum 2.75 Zinc 7.14 Nylon 6/6 – 33% Glass Fiber 1.39 PPS – 40% Glass Fiber 1.65 Polyethersulfone – 30% Glass Fiber 1.58 Thermoset Polyester 1.75-1.95 Vinyl Ester 1.75-1.95 General Purpose Phenolic 1.40-1.75 High-Performance Phenolic 1.40-1.80
    • Cost Analysis – Price/Pound (March 2008)
    • Cost Analysis – Price/Cubic Inch (March 2008)
    • Material Choices in Thermosets
      • Phenolics
      • Aminos (Melamine, Urea)
      • Unsaturated Polyesters
      • Polyurethane
      • Allyls (DAP, DAIP)
      • Polyimides
      • Silicones
      • Epoxy
      • Casein
      Cross Over point is Phenolic equals PPS
    • Phenolic
      • Two-Stage (Novalac)-Shelf Life Infinite (normal storage)
        • Produced with Acid Catalyst and a portion of the required Formaldehyde
        • Product is a brittle compound that will not cure with heat and is considered a thermoplastic
        • Hardener is required to complete cure which is usually Formaldehyde in the form hexamethyleneteramine (hexa), which upon heatings forms ammonia and formaldehyde
      • Two-Stage (Novalac) Properties
        • Broken down in to General Purpose, Non-bleeding, Heat Resistant, Impact, and Electrical
        • They Maintain dimension stability for an indefinite amount of time at normal atmospheric conditions
        • High degree of resistance to deformation under load
    • Phenolics – Advantages
      • Excellent Dimensional Stability – Low Coefficient of Thermal Expansion
      • Very High Surface Hardness – Good Wear and Friction Properties
      • Excellent retention of physical properties at high temperature (300F continuous, 500F short bursts-Post Bake 340F Continuous)
      • Good Insulator both electrically and thermally
      • Multiple Fillers (Inorganic and Polymeric)
      • Highly Resistant to Solvents and Automotive Fluids
    • Phenolics - Disadvantages
      • Single Stage Resins Unstable at Temperatures Above 45 F Making Production Sensitive
      • Two-Stage Resins Available Only in Black and Dark Colors Such As Brown, Dark Blue, Dark Red and Green
      • Susceptible to Electrical Tracking
      • Usually Require Post-Baking to Achieve Optimal Properties (Two-Stage Resins)
      • Very Low Impact Resistance
      • Two-Stage expels Ammonia
    • Urea – Properties
      • Any Color
      • High gloss and durable
      • High mechanical strength, heat resistance, fire resistance, good electrical arc, and arc tracking
      • Scratch Resistant
      • Readily used in compression and transfer, requires modification for injection molding to extend flow “life”
      • Heat Resistance up to 170F
    • Melamine - Properties
      • Similar to Urea but Higher heat resistance, chemical, moisture, electrical, and scratch resistance
      • Multiple fillers can be used (wood flour, minerals, and cellulose fiber)
      • FDA approved for food contact even at high temperature
      • High surface gloss
      • Bright sharp colors that are light fast
      • Extreme Hardness
      • Excellent Arc Resistance
    • Polyester Chemical Forms
      • Ortho: Most widely used
      • Iso: Better mechanical properties and chemical resistance than Ortho more costly
      • Bisphenol A fumarates: Very good chemical and thermal properties – considered high performance
      • Chlorendics: Excellent chemical properties combined with some flame retardancy
      • Vinyl esters: Exceptional mechanical and chemical properties but higher cost
    • Polyester - Forms
      • Free-flowing granular
      • Pelletized (PMG)
      • Putty or rope-type extrudates
      • Sheet molded compound (SMC)
      • High bulk factor compounds (BMC)
      • Thick molding compounds (TMC)
    • Polyesters - Advantages
      • Available In A Wide Range of Colors
      • Excellent Electrical Properties Combined with Ignition Resistance
      • Good Toughness for Thermosets
      • Can be Molded in to Complex Shapes
    • Polyesters - Disadvantages
      • Maturation Process Required Prior to Molding
      • Styrene Crosslinking Agent Is Volatile Causing Viscosity Changes As A Function of Storage Time
    • Thermoset Injection
    • Thank you ! NASHOTAH OPERATIONS N44 W33341 Watertown Plank Rd. Nashotah, WI 53058 Phone: 262.367.5200 This is the proprietary property of Dickten Masch Plastics and intended solely for internal use of specified customer/prospects only. Use of this information outside the scope of intended use is strictly prohibited. Email: dickten@dicktenplastics.com Website: www.dicktenplastics.com ANKENY OPERATIONS 3401 S.E. Convenience Blvd Ankeny, Iowa 50021   Phone: 515 964-2675 MONTERREY OPERATIONS Boulevard TLC#200 Parque Industrial, STIVA Aeropuerto Apodaca, Nuevo Leon, CP66600 Mexico