1. 1
2016
900 E. Vienna Avenue, Milwaukee, WI 53212 P: 414-964-5200 www.cornerstonecomposites.com
2. Stronger Solutions
As a team of engineers, we believe that stronger solutions are always worth
striving for. We help nimble, open-minded manufacturers advance their
products by replacing metal and thermoplastic parts with higher performance,
customized composite formulations.
Core Statement
4. Stronger Solutions
Thermoset Composites
Thermoset composites often fill in the performance
region between common thermoplastics and metals.
PE ABS Nylon PC GFNylon PET PPS PEI PEEK Al Zinc Mg Mild Steel Hard Steel
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5. Stronger Solutions
What are they?
• Mixtures of polymer resins, catalysts and reinforcements that react and cross-link when exposed to thermal
energy, hence – “thermoset”.
• Close cousin to “chemical set” composites which cross-link at room temperature when mixed with a catalyst.
• As opposed to Thermoplastics, which can be melted, solidified and melted again with heat cycles, Thermosets
are permanently solidified upon cross-linking.
• Thermoset materials get their unique properties from the formation of three-dimensional covalent bonds
between the molecules – “cross-linking”.
• Different from Thermoplastics, whose molecule-to-molecule bonds are largely electrostatic attractions and
entanglements.
6. Stronger Solutions
When should you use Thermoset?
High Stiffness Elevated Temperatures
High Strength Low Creep
Structural Aesthetics Dielectric Applications
Dimensional Stability Chemical Resistance
7. Stronger Solutions
Opposed to Thermoplastics
Opposed to Metals
Mold to net shape – no machining Consolidate parts & functions
Chemical resistance Eliminate painting
Lower processing costs
Stiffer Stronger per $
Higher thermal performance Low shrink
Low residual stress Thermal Stability
Low creep
9. Stronger Solutions
• Bulk Molding Compound (BMC)
• Viscous, putty-like compound for
injection or compression molding
• Highly-filled and reinforced
with short glass fibers
• Injection or compression-molded
• Glass reinforcement represents
between 10% and 30%
• Mold in-color, or apply powder-coat
or wet paint
10. Stronger Solutions
• Sheet Molding Compound (SMC)
• Similar chemistry to BMC
• Longer fiber length than BMC
• Glass reinforcement represents
between 20% and 50%
• Sheathed top-and-bottom
with carrier film
• Typically compression molded into
complex shapes
• 400,000,000 lbs. used in
automotive and heavy truck
applications in 2006 (ACMA)
11. Stronger Solutions
• Use molded composite materials to replace cast,
fabricated, extruded and stamped metal
components:
•
• Reduce weight
• Reduce cost
• Manufacture to net shape
• Remove finishing operations
• Painting
• Machining
• Add molded-in features
• Consolidate components
Metal Replacement
Commercial Saw Table – replaced
extruded aluminum
Base for a Commercial Food Slicer replaced cast
aluminum for a savings of 50%
Molded composite Hopper for wood stove eliminated a
complex and costly steel fabrication
12. Stronger Solutions
These materials retain their mechanical
properties at elevated temperatures well
beyond commercial thermoplastics.
Virtually no creep
Do not soften or melt
Very high ignition temperature
Are thermal insulators
High Temperature Performance
Oven Trays for Re-therm food
preparation
Small Engine Valve Cover – low creep,
maintains seal at elevated operating
temperatures
Commercial Hot-Melt Glue Gun –
operates at 350
Heated Products are a natural
application for Thermoset
Composites - with high
temperature and low flammability
requirements
13. Stronger Solutions
Dielectric Applications
Thermoset Composites are
intrinsically dielectric:
Maintain dielectric strength at
elevated temperatures
Often used to replace ceramics –
less brittle
Can be used to encapsulate
conductors
Welder Switch – high current load
Engine Block Connector – maintain
dielectric strength at high temperature
in oily, wet environment
Mass Transit “3rd Rail” Conductors – replaces ceramic
in very tough environment.
14. Stronger Solutions
Lighting and Office
Lighting is a natural market for Thermoset
Composites:
High temperature exposure
Non-yellowing
High Dielectric
Thermal insulator
Can be metallized for reflectors
Keyboard Tray for Articulating
Mechanism – replaced wood
composite. Very flat. Very stiff.
Recessed Lighting Baffles
Stylized Florescent Baffle
15. Stronger Solutions
Food Preparation
Thermosets find a
natural home in the food
industry:
High thermal
capacity
FDA & NSF
compliance
Resistance to
chemical cleaning
products
Replaces Stainless
Steel and Aluminum
Base for Commercial Deli Slicer – replaced cast
aluminum that required machining and polishing.
Offers huge price savings.
Molded Composites make an
attractive, cleanable, NSF-
compliant surface for buffet
service
16. Stronger Solutions
Unique Applications
Pack Frame – traditional material was
fabricated aluminum
Commercial Flooring Nailer – provides toughness
that aluminum could not
A polymer composite Heating Element –
functions at 300?F. Molded from
engineered phenolic composite.
17. Stronger Solutions
Mechanical Attributes of Thermosets
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100ModulusRetention%
Temperature C
Modulus vs Temperature
Nylon (Crystalline TP) Phenolic (TS)
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Phenolic PPS Nylon 6/6 PBT PET
%DimensionRetained
Compressive Creep @ 150C
