Plastic molding

Author: Hu Jun
Publisher:
Publishing Date: 2005-05-01
Features: This book provides a comprehensive introduction to the raw materials, production processes, molding processes, and related equipment used in the compression molding industry in China; it also specifically discusses the design of compression molding products and the design of molding dies. It introduces the main application areas and practical examples of various compression molding products. The book focuses on introducing basic knowledge, with content that is simple, practical, and advanced, making it suitable for production and technical personnel in the compression molding industry. It also has some reference value for related plastic professional designers.
Table of Contents
Table of Contents
Chapter 1 Introduction
1.1 Introduction to Compression Molding Process
1.2 Classification of Compression Molding Process
1.3 Brief History and Current Status of Compression Molding Process
1.4 Introduction to Laminating Molding Process
1.5 Introduction to Transfer Molding Process
Review Questions
Chapter 2 Raw Materials for Molding Compounds
2.1 Thermosetting Synthetic Resins
2.1.1 Basic Requirements for Resins in Compression Molding
2.1.2 Common Types of Thermosetting Resins
2.2 Reinforcing Materials
2.2.1 Glass Fiber
2.2.2 High-Silicon-Oxygen Fiber
2.2.3 Other Fibers
2.2.4 Surface Treatment of Fibers
2.3 Fillers
2.3.1 Principles for Selecting Fillers
2.3.2 Types of Fillers
2.4 Other Components and Additives
2.4.1 Initiators
2.4.2 Chemical Thickeners
2.4.3 Low-Shrinkage/Low-Waveguide Additives
2.4.4 Pigments
2.4.5 Mold Release Agents
2.4.6 Diluents and Crosslinking Agents
Review Questions
Chapter 3 Preparation of Molding Compounds
3.1 Preparation of Molding Powders
3.1.1 Dry Method Production
3.1.2 Wet Method Production
3.2 Preparation of Pellet (Bulk) Molding Compounds
3.2.1 Raw Materials for Pellet (Bulk) Molding Compounds
3.2.2 Production Equipment for Pellet (Bulk) Molding Compounds
3.2.3 Production Process of Pellet (Bulk) Molding Compounds
3.2.4 Factors Affecting Mixing Process
3.2.5 Operation Management of Pellet (Bulk) Molding Compound Production Process
3.3 Preparation of Sheet Molding Compounds
3.3.1 Production Equipment for Sheet Molding Compounds
3.3.2 Production Process of Sheet Molding Compounds
3.3.3 Common Defects and Solutions in Sheet Molding Compound Production Process
3.3.4 Quality Management of Sheet Molding Compound Production Process
3.4 Preparation of Adsorbed Preform Molding Compounds
3.4.1 Raw Materials for Adsorbed Preform Molding Compounds
3.4.2 Equipment for Adsorbed Preform Molding Compounds
3.4.3 Main Components of Preform Equipment
3.4.4 Several Related Issues in Preform Production Process
3.5 Preparation of Short Fiber Molding Compounds
3.5.1 Composition of Short Fiber Molding Compounds
3.5.2 Shortening of Glass Fiber
3.5.3 Preparation of Short Fiber Molding Compounds
3.5.4 Issues to Pay Attention to in Short Fiber Molding Compound Production Process
3.6 Storage, Quality Control, and Performance Testing of Molding Compounds
3.6.1 Storage of Molding Compounds
3.6.2 Quality Control of Molding Compounds
3.6.3 Methods for Performance Testing of Molding Compounds
Review Questions
Chapter 4 Compression Molding Process
4.1 Molding Compound Molding Process Properties
4.1.1 Flowability
4.1.2 Curing Rate
4.1.3 Shrinkage Rate
4.1.4 Compression Ratio
4.2 Compression Molding Process
4.2.1 Preparation of Molding Materials
4.2.2 Compression Molding Process
4.2.3 Post-Processing of Products
4.2.4 Auxiliary Processing Operations
4.3 Compression Molding Process Conditions
4.3.1 Compression Temperature
4.3.2 Compression Pressure
4.3.3 Compression Time
4.3.4 Common Problems and Solutions in Compression Molding Process
4.4 Compression Molding Process of Common Molding Compounds
4.4.1 Compression Molding Process of Pellet (Bulk) Molding Compounds
4.4.2 Compression Molding Process of Sheet Molding Compounds
4.4.3 Compression Molding Process of Adsorbed Preform Molding Compounds
4.4.4 Compression Molding Process of Short Fiber Molding Compounds
4.4.5 Oriented Laying Compression Molding Process
Review Questions
Chapter 5 Transfer Molding
5.1 Principle of Transfer Molding
5.1.1 Basic Principle of Transfer Molding
5.1.2 Characteristics of Transfer Molding
5.2 Forms of Transfer Molding
5.2.1 Slot-Type Transfer Molding
5.2.2 Plunger-Type Transfer Molding
5.2.3 Screw-Type Transfer Molding
5.3 Raw Materials for Transfer Molding
5.3.1 Matrix Resins for Transfer Molding
5.3.2 Reinforcing Materials for Transfer Molding
5.3.3 Processing of Preforms
5.3.4 Adhesives
5.4 Transfer Molding Process
5.4.1 Transfer Molding Process Flow
5.4.2 Main Process Parameters of Transfer Molding
5.4.3 Defects and Solutions in Transfer Molding Products
5.5 Transfer Molding Equipment and Dies
5.5.1 Transfer Molding Machines
5.5.2 Transfer Molding Dies
5.5.3 Pressure Check of Transfer Molding Machines
5.5.4 Structure of Transfer Molding Dies
5.6 Applications of Transfer Molding
5.6.1 Aerospace
5.6.2 Railway Transportation
5.6.3 Automotive Industry
5.6.4 Construction Industry
5.6.5 Industrial and Commercial Fields
5.6.6 Shipbuilding
5.6.7 Other Fields
Review Questions
Chapter 6 Molding of Major Thermosetting Resins
6.1 Phenolic Resin
6.1.1 Composition of Phenolic Molding Compounds
6.1.2 Properties of Phenolic Molding Compounds
6.1.3 Representation of Phenolic Resin Molding Powders
6.1.4 Characteristics and Uses of Phenolic Molding Compounds
6.1.5 Molding of Phenolic Molding Compounds
6.2 Amino Resin
6.2.1 Composition of Amino Molding Compounds
6.2.2 Properties of Amino Molding Compounds
6.2.3 Molding Process of Amino Molding Compounds
6.2.4 Uses of Amino Molding Powders
6.3 Unsaturated Polyester Resin
6.3.1 Composition of Unsaturated Polyester Molding Compounds
6.3.2 Properties of Unsaturated Polyester Molding Compounds
6.3.3 Molding Process of Unsaturated Polyester Molding Compounds
6.3.4 Uses of Unsaturated Polyester Molding Compounds
6.3.5 Comparison of SMC and Phenolic SMC Molding Technology
6.4 Epoxy Resin
6.4.1 Composition of Epoxy Molding Compounds
6.4.2 Properties of Epoxy Molding Compounds
6.4.3 Molding Process of Epoxy Molding Compounds
6.4.4 Applications of Epoxy Molding Compounds
6.5 DAP Resin
6.5.1 Properties of DAP Molding Compounds
6.5.2 Molding Process of DAP Molding Compounds
6.5.3 Applications of DAP Molding Compounds
6.6 Silicone Resin
6.6.1 Composition and Properties of Silicone Resin Molding Compounds
6.6.2 Molding Process of Silicone Resin
6.6.3 Applications of Silicone Resin Molding Compounds
6.7 Examples of Compression Molding
Review Questions
Chapter 7 Molding of Thermoplastic Plastics
7.1 Ultra-High Molecular Weight Polyethylene
7.1.1 Properties of Ultra-High Molecular Weight Polyethylene
7.1.2 Molding Process
7.1.3 Applications of Ultra-High Molecular Weight Polyethylene Plastics
7.2 Fluoroplastics
7.2.1 Polytetrafluoroethylene
7.2.2 Polyvinylidene Fluoride
7.2.3 Polyvinylidene Chlorofluoride
7.2.4 Polyvinylidene Fluoride
7.2.5 Tetrafluoroethylene-Ethylene Copolymer
7.3 Polyimide
7.3.1 Homopolymer Polyimide
7.3.2 Ether-Anhydride Type Polyimide
7.3.3 Polyamide-Polyimide
7.3.4 Furan-Imide Type Polyimide
7.4 Polyphenylene Ether
7.4.1 Properties of Polyphenylene Ether
7.4.2 Molding of Polyphenylene Ether
7.4.3 Applications of Polyphenylene Ether
7.5 Polyetheretherketone
7.5.1 Properties of Polyetheretherketone
7.5.2 Molding of Polyetheretherketone
7.5.3 Applications of Polyetheretherketone
7.6 Polysulfone
7.6.1 Properties of Polysulfone
7.6.2 Molding of Polysulfone
7.6.3 Applications of Polysulfone
7.7 Examples of Compression Molding
7.7.1 Overview of Production of Filled Polytetrafluoroethylene Products
7.7.2 Raw Materials and Typical Formulas
7.7.3 Main Equipment
7.7.4 Production Process
7.7.5 Product Properties
7.7.6 Differences Between Production Technology of Filled and Unfilled Polytetrafluoroethylene Products
Review Questions
Chapter 8 Foam Plastic Compression Molding
8.1 Overview
8.2 Basic Raw Materials of Foam Plastics
8.2.1 Resins
8.2.2 Blowing Agents
8.2.3 Plasticizers
8.2.4 Other Additives
8.3 Foam Plastic Blowing Molding Principle
8.3.1 Formation of Pores
8.3.2 Enlargement of Pores
8.3.3 Stability of Pores
8.4 Foam Plastic Compression Molding Process
8.4.1 Styrene Foam Plastic Compression Molding
8.4.2 Polyethylene Foam Plastic Compression Molding
8.4.3 Polyvinyl Chloride Foam Plastic Compression Molding
8.5 Examples of Compression Foaming Molding Applications
8.5.1 Polyethylene High-Expandable Calcium Plastic Boards
8.5.2 EPS Plastic Packaging Blocks
8.5.3 Compression Molding of Polytetrafluoroethylene Foam Rods
Review Questions
Chapter 9 Design of Compression Molding Products
9.1 Draft Angle
9.2 Wall Thickness
9.3 Radius
9.4 Reinforcing Ribs
9.5 Support Surfaces and Ears
9.6 Inserts
9.7 Holes
9.8 Threads
9.9 Dimensional Accuracy
Review Questions
Chapter 10 Compression Molding Dies
10.1 Structure and Classification
10.1.1 Structure
10.1.2 Classification
10.2 Selection of Die Structure
10.2.1 Plastic Properties
10.2.2 Product Shape
10.2.3 Product Batch
10.2.4 Die Machining Methods
10.2.5 Press Structure and Performance
10.3 Design of Forming Part Structure
10.3.1 Punch Structure
10.3.2 Die Structure
10.3.3 Fit of Punch and Die
10.3.4 Core Structure
10.3.5 Feeding Chamber Structure
10.3.6 Calculation Methods for Part Dimensions
10.4 Other Structures
10.4.1 Guiding Mechanism
10.4.2 Ejection Mechanism
10.4.3 Core Pulling Mechanism
10.5 Heating Devices
10.5.1 Electric Heating
10.5.2 Steam (or Hot Water) Heating
10.5.3 Gas (or Natural Gas) Heating
10.6 Dies for Molding of Special Plastics
10.6.1 Cold Compression Molding Dies
10.6.2 Foam Plastic Dies
Review Questions
Chapter 11 Hydraulic Presses
11.1 Working Principle of Hydraulic Presses
11.2 Structure and Performance Requirements of Hydraulic Presses
11.3 Technical Parameters of Hydraulic Presses
11.4 Operation and Maintenance of Hydraulic Presses
Review Questions
Chapter 12 Laminating Process
12.1 Raw Materials for Laminating
12.1.1 Resins
12.1.2 Reinforcing Materials
12.1.3 Auxiliary Materials
12.1.4 Solvents
12.2 Laminating Products Forming Equipment
12.2.1 Impregnation and Drying Equipment
12.2.2 Hot Press
12.2.3 Loading and Unloading Mechanism
12.2.4 Flipboard and Transmission Mechanism
12.2.5 Processing and Finishing Equipment
12.3 Preparation of Prepregs
12.3.1 Pretreatment of Reinforcing Materials
12.3.2 Impregnation
12.3.3 Drying
12.3.4 Quality Inspection of Adhesive Materials
12.4 Laminating Process
12.4.1 Layering
12.4.2 Hot Pressing Process
12.4.3 Demolding
12.4.4 Post-Processing
12.4.5 Heat Treatment
12.4.6 Common Product Quality Problems, Causes, and Solutions in Laminating Process
12.5 Application of Laminated Plates and Machining of Laminated Products
12.5.1 Application of Laminated Plates
12.5.2 Machining of Laminated Products
12.6 Laminating of Common Thermosetting Plastics
12.6.1 Phenolic Resin
12.6.2 Amino Resin
12.6.3 Epoxy Resin
12.6.4 Silicone Resin
12.6.5 Polyimide
12.7 Examples of Laminating Process
12.7.1 Molding Process of PVC Laminated Hard Plate
12.7.2 Molding Process of Paper-Based Phenolic Laminated Plate
12.7.3 Molding Process of Copper-Clad Laminate
Review Questions
Main References