Part & Mold Design Guide - Reaction Injection Molding

90 Pages·2008·4.52 MB·English

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Quick Design Reference Guide for RIM
Elastomers Rigid Rim Composites
Solid Bayfex Foamed Solid Solid PRISM Foamed Solid
System Baydur Baydur GS System Baydur STR/F Baydur STR/C
Parameters (Unflled) System System (Thin Walled) System System
Part Design
(t)Wall Thickness (in) 0.2 – 1.0 0.2 – 1.5 0.25 – 4.0 0.125 – 0.5 0.125 – 0.25 0.09 – 0.15
a Use box beam Use box beam
Rib Thickness at Root 0.75t t t 0.75t
or corrugation or corrugation
0.5 min 0.5 min 0.5 min 0.5 min
Draft (degrees) This is +0.25/inch +0.25/inch +0.25/inch +0.25/inch
function of Part Draw or greater than greater than greater than greater than 1.0 min 1.0 min
Depth one inch of one inch of one inch of one inch of
draw draw draw draw
Molded Holes/Slots Yes Yes Yes Yes No No
Use side pull Use side pull Use side pull
Undercuts Slight undercuts or removable or removable or removable No No
insert insert insert
Snap Fits Possible Possible Possible Possible No No
Fillets (Inner Radius)(in) 1/16 1/8 1/8 1/16 1/4 1/4
Finishing
No Class A, use
Best Surface Class A Class A N/A Class A Class A with veil
texture
Use bolt and
Screw Assembly Thread cuts skin Thread cutting Thread cutting Thread cutting Thread cutting
b
nut
Mold Design and Processing Parameters
Metal preffered Metal preffered Metal preffered Metal preffered
Material of Construction (depending on (depending on (depending on (depending on Steel Steel
prod. volume) prod. volume) prod. volume) prod. volume)
Preferred Gating Fan Dam Dam Dam Center/Direct Center/Direct
c
Shot Time, Max. (sec) 2 (9 ) 9 15 5 5 15
Mold Pressure (psi) 100 100 100 100 200 200
Mold Temperature (°F) 140 – 160 140 – 160 140 – 160 140 – 160 130 – 140 175 – 185
Physical Properties
53.000 – 130,000 – 270,000 – 150,000 –
Flexural Modulus (psi) 5,000 – 100,000 Up to 2,000,000
240,000 190,000 310,000 750,000
3
Part Density (lb/in ) 60 – 65 15 – 55 63 – 68 61 – 67 20 – 40 90 – 110
Flexural Strength (psi) N/A 3,000 – 12,000 5,300 – 7,700 9,300 – 10.300 3,500 – 17,000 50,000
Tensile Strength (psi) 1,900 – 4,000 1,000 – 4,800 3,600 – 5,300 5,500 – 6,600 2,500 – 9,000 26,000
Elongation at Break (%) 100 – 360 6 – 10 16 – 29 11 – 12 2.5 2.5
DTUL at 66 psi (°F) N/A 160 – 212 140 – 215 190 – 205 205 400
Hardness (Shore D) 30 – 69 40 – 81 70 – 75 73 – 75 60 – 70 60 – 70
% Reinforcement 0 – 25 N/A N/A N/A 20(mat) 55(mat)
a b
Root includes both radii. Can also screw through to metal substrate.
c
Longer shot times are possible with a Bayfex XGT system, which has an extended gel time.
TABLE OF CONTENTS
Introduction Chapter 4
PART DESIGN FOAMED MATERIALS
5 The RIM Process 31 Foam Rise and Flow
6 Material Descriptions 31 Wall Thickness
32 Rib Design and Confguration
Chapter 1 33 Radii/Fillets
MATERIAL SELECTION CRITERIA 33 Bosses
9 Aesthetic Considerations 34 Structural Analysis Considerations
10 Functional Considerations
10 Economic Considerations Chapter 5
COMPOSITE MATERIALS
Chapter 2 35 Glass Mat
GENERAL PART DESIGN 36 Reinforcements
13 Part Stiffness 36 Radii/Fillets
13 Wall Thickness 37 Pads
15 Ribbing Design and Confguration 37 Preforms
17 Ribbing Direction 38 Finishes
18 Draft
19 Bosses Chapter 6
21 Holes, Grooves and Slots POSTMOLDING OPERATIONS
23 Inserts 39 Finishing
23 Metal Stiffening Inserts 39 Pigmentation
24 Wood Stiffening Inserts 40 In-Mold Coatings
24 Threaded Inserts 40 Patching
25 Undercuts 40 Postmold Painting
25 Snap Fits, Wire Guides and Hinges 40 Textures
26 Fillers 41 Decals and Silk-Screening
27 Warpage in Part Design 41 Assembly Operations
27 Creep Considerations 41 Screws
27 Fatigue Considerations 42 Adhesives
28 Back Molding 43 P0stfabrication
43 Nailing/Stapling/Planing
Chapter 3 43 Recycling Polyurethanes
SOLID MATERIALS
29 Wall Thickness
29 Rib Design and Confguration
30 Radii/Fillets
1
TABLE OF CONTENTS
Introduction Chapter 4
PART DESIGN FOAMED MATERIALS
5 The RIM Process 31 Foam Rise and Flow
6 Material Descriptions 31 Wall Thickness
32 Rib Design and Confguration
Chapter 1 33 Radii/Fillets
MATERIAL SELECTION CRITERIA 33 Bosses
9 Aesthetic Considerations 34 Structural Analysis Considerations
10 Functional Considerations
10 Economic Considerations Chapter 5
COMPOSITE MATERIALS
Chapter 2 35 Glass Mat
GENERAL PART DESIGN 36 Reinforcements
13 Part Stiffness 36 Radii/Fillets
13 Wall Thickness 37 Pads
15 Ribbing Design and Confguration 37 Preforms
17 Ribbing Direction 38 Finishes
18 Draft
19 Bosses Chapter 6
21 Holes, Grooves and Slots POSTMOLDING OPERATIONS
23 Inserts 39 Finishing
23 Metal Stiffening Inserts 39 Pigmentation
24 Wood Stiffening Inserts 40 In-Mold Coatings
24 Threaded Inserts 40 Patching
25 Undercuts 40 Postmold Painting
25 Snap Fits, Wire Guides and Hinges 40 Textures
26 Fillers 41 Decals and Silk-Screening
27 Warpage in Part Design 41 Assembly Operations
27 Creep Considerations 41 Screws
27 Fatigue Considerations 42 Adhesives
28 Back Molding 43 P0stfabrication
43 Nailing/Stapling/Planing
Chapter 3 43 Recycling Polyurethanes
SOLID MATERIALS
29 Wall Thickness
29 Rib Design and Confguration
30 Radii/Fillets
3
TABLE OF CONTENTS
Introduction
MOLD DESIGN Chapter 12
MOLD FINISHING
Chapter 7 73 Mold Construction Materials and Fabrication Techniques
GENERAL MOLD DESIGN CONSIDERATIONS 73 Material Selection
47 Part Size/Clamping Pressure 74 Steel
48 Mold Costs 74 Aluminum
49 Shrinkage 74 Zinc Alloys (Kirksite)
49 Dimensional Tolerances 74 Nickel Shells
74 Epoxy Molds
Chapter 8 75 Mold Construction Techniques
GATE DESIGN 75 Milled Block
51 Mixing Head 75 Structural Components
52 Aftermixers 75 Cast
53 Edge Gating 75 Extruded Aluminum Profles
54 Foamed Systems 75 Nickel Plating
54 Dam Gates 76 Surface Treatments for Molds
55 Solid Systems 76 Textures and Finishes
56 Fan Gates
58 Ball Check Chapter 13
58 Center-Gated Direct Fill TECHNICAL SUPPORT
77 Health and Safety Information
Chapter 9 77 Design and Engineering Expertise
PARTING-LINE CONSIDERATIONS 78 Technical Support
62 Mold Sealing 78 Design Review Assistance
63 Mold Venting 78 Application Development Assistance
64 Mold Filling 78 Product Support Assistance
78 Regulatory Compliance
Chapter 10 79 RIM Plastics Recycling
OTHER MOLD DESIGN CONSIDERATIONS 79 For More Information
65 Mold Temperature Control
66 Demolding Methods APPENDICES
68 Movable Cores and Inserts 80 List of Figures and Tables
69 Mold Design for Slots 82 Index
69 Shear Edges
Chapter 11
SPECIAL MOLDS
71 Multiple-Cavity Molds
72 Self-Contained Molds
4
Introduction
TABLE OF CONTENTS PART DESIGN
Today, various Reaction Injection The extensive number of RIM Specifc system data and typical
Molding (RIM) polyurethane systems polyurethane systems with their property information have not
are replacing many traditional various physical and mechanical been included in this manual
materials because of their inherent properties can make selecting the right except as examples for general
advantages, including: system diffcult. The purpose of this information. All values that appear
manual is to help you – the design in this manual are approximate
• Large–part molding; . Wall–thickness engineer, product designer and others and are not part of the product
variations; who work with RIM polyurethane specifcations. Do not use this data
materials – make practical design for product specifcation. For more
• Excellent encapsulation capabilities; decisions. specifc information on a particular
system, please read the appropriate
• Excellent surface reproducibility and This manual is divided into two BaySystems Product Information
in–mold paint fnishing; sections: part design and mold Bulletin (PIB). Published data should
design. The section on part design be used to screen potential material
• Good dimensional stability; begins with a brief discussion of candidates. Your understanding of
the RIM polyurethane process and materials and processing and your
• Good chemical resistance; design considerations common to all part’s requirements determines the
RIM polyurethane systems. Unique suitability of a material for your
• Good weatherability. properties and design guidelines product or application. Ultimately,
for various polyurethane systems material selection must be based upon
Generally, RIM processing uses are discussed next, followed by your prototype testing under actual,
less expensive molds, less energy design considerations for assembly end–use conditions.
and lower–tonnage presses than and postmolding operations. The
thermoplastic processing. These second section of this book contains Bayer MaterialScience offers a full
characteristics add up to superior information on mold, gate and runner range of RIM polyurethane systems,
design, economic and processing design. including foamed, solid and structural
fexibility. composite materials. As a service to
Many rules of thumb appear in the our customers, we also have technical
text. Naturally, there may be some personnel ready to help you with
exceptions to these rules of thumb part design and production. A list of
or times when one conficts with these services appears in the back
another. If this happens, talk with your of this booklet. Please feel free to
mold maker/designer and BaySystems contact us with specifc questions at
personnel for appropriate action. While 412 111-2000.
this manual provides a good overview
of the topics you should address
when designing for polyurethane
parts, you should also have a good
understanding of polyurethane
systems before making fnal decisions.
For a quick reference, see the part–
design matrix on the inside back cover
for key information.
5
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6
Introduction
PART DESIGN
THE RIM PROCESS
In contrast to thermoplastics where a In fgure P–1, the pressurized day
molten plastic is compacted in a mold tanks typically hold from 30 to 250
and then solidifes upon cooling, RIM gallons of isocyanate or polyol.
systems are composed of two liquid Recirculation pumps and agitators
components that chemically react in maintain a homogeneous blend of
the mold. The liquids, isocyanate and the individual components. The heat
polyol, are commonly referred to as exchangers maintain components’
the “A side” and “B side” components, temperature. Either high–pressure,
respectively, in the United States. metering pumps or hydraulically
In Europe, these demarcations are driven chemical cylinders – commonly
reversed. A matched set of “A” and referred to as “lances”– meter
“B” components is referred to as a isocyanate and polyol into the mixing
“RIM system.” head. Flow rates and pressures are
precisely controlled to ensure high–
Generally, the “B” component contains quality parts.
additives such as stabilizers, fow
modifers, catalysts, combustion The mix head contains injector nozzles
modifers, blowing agents, fller, which impinge the isocyanate and
pigments and release agents to polyol at ultra–high velocity to provide
modify physical characteristics in excellent mixing. Additional mixing is
the fnal part. When the “A” and “B” accomplished using an after–mixer,
components combine, the isocyanate typically constructed inside the mold.
reacts with the hydroxyl in the polyol
to form a thermosetting polyurethane
polymer. This reaction is exothermic:
when the “A” and “B” components
combine, heat is released. To prevent
scorching and/or other part defects,
cooling lines on the mold help
dissipate this heat.
7
Polyurethane Systems Classified by Flexural Modulus Figure P-2
BAYDUR STR/C
Solid
Composites
BAYDUR STR/C
Foamed
Composites
PRISM
Rigid
Solids
BAYDUR
Rigid
Foams
R
BAYFLEX
R
Elastomeric
I
M Solids
0 300 600 900 1200 1500 1800
3
Flexural Modulus (10 psi)
MATERIAL DESCRIPTIONS
The degree of rigidity usually defnes systems exhibit good toughness and • Foamed polyurethane systems use
a polyurethane system, placing it dimensional stability throughout a a blowing agent to make parts
in one of two categories: rigid or wide temperature range and have with a higher–density skin and a
elastomeric. A rigid polyurethane excellent corrosion, abrasion, wear and lower density, microcellular core
material generally has a higher fexural cut resistance. in a sandwich–like composition.
modulus and degree of hardness. Baydur structural foam and other
This class of materials normally offers Physical properties for these two rigid systems have hard, solid
good thermal resistance, electrical categories are not absolute and skins and are found in business
properties, chemical resistance and the fexural moduli ranges of these machines, electronic and medical
acoustical insulation. An elastomeric materials overlap (see fgure P–2). housings, automobile spoilers, skis
polyurethane system is often found in Within these two classifcations, and other load–bearing applications.
applications requiring superior impact the are three types of polyurethane All foamed RIM materials are
strength. Elastomeric polyurethane systems (see fgure P–3): microcellular systems, having cells
as small as 0.001 inch.
8
Types of Polyurethane Materials
Introduction
PART DESIGN
• Solid polyurethane systems do
Figure P-3 Types of Polyurethane Materials
not use blowing agents, resulting
in a homogeneous, rigid or
elastomeric plastic. Bayfex solid
elastomeric materials are used in
many applications, including the
automotive, specialty transportation,
construction, agriculture and
Solid
recreational industries. Common
parts include fenders, fascias,
trims and vertical panels. Glass or
mineral fllers can be added to solid
elastomers for improved stiffness.
This is commonly referred to as
Reinforced RIM or RRIM.
Self-Skinning Foam
PRISM solid polyurethane systems
have many properties similar to
those of engineering thermoplastics.
They can be used to mold many
thicker or thin–walled parts and
may be more economical than
thermoplastics.
Composite
• Structural composite polyurethane
systems are solid or foamed
materials, molded in combination
with long–fber reinforcements,
such as glass mat, to improve the
system’s mechanical characteristics.
Sometimes referred to as “SRIM,”
for Structural RIM, these systems
have extremely high stiffness and
high impact strength because of the
mat. Typical applications include
door panels, shelves, automotive
horizontal/ load–bearing panels and
recreational equipment parts
9