Cold Moldings

Highest thermal performance with PPS compounds requires that parts be molded under conditions leading to a high level of crystallinity. Glass-filled PPS compounds can be molded so that crystalline or amorphous parts are obtained. Mold temperature influences the crystallinity of PPS parts. Mold temperatures below approximately 93°C produce parts with low crystallinity and those above approximately 135°C produce highly crystalline parts. Mold temperatures between 93 and 135°C yield parts with an intermediate level of crystallinity. Part thickness may also influence the level of crystallinity. Thinner parts are more responsive to mold temperature. Thicker parts may have skin-core effects. When thick parts are molded in a cold mold the skin may not develop much crystallinity. The interior of the part, which remains hot for a longer period of time, may develop higher levels of crystallinity. 

Mold temperature can vary widely. Typical temperatures range from 40 to 150°C. Higher mold temperatures favor polymer crystallisation and result ia more dimensionally stable parts. Crystallinity can be developed ia parts molded ia cold molds by annealing at approximately 200°C. 

Cold molding The fashioning of an unheated mixture in a mold under pressure. The article is then heated to effect curing. 

In injection molding, the polymer is fed from a hopper into a heated barrel where it softens and becomes a viscous melt. It is then forced under high pressure into a relatively cold mold cavity where the polymer has sufficient time to solidify. Then the mold is opened and the fabricated part is ejected. The cycle of operation is then repeated. 

Residual stress There is a condition that develops, particularly in products with thin walls. This is a frozen-in stress, a condition that results from the filling process. The TP flowing along the walls of the mold is chilled by heat transferring to the cold mold walls and the material is essentially set (approaching solidification). The material between the two chilled skins formed continues to flow and, as a result, it will stretch the chilled skins of plastics and subject them to tensile stresses. When the flow ceases, the skins of the product are in tension and the core material is in compression that results in a frozen-in stress condition. This stress level is added to any externally applied load so that a product with the frozen-in stress condition is subject to failure at reduced load levels. 

Material Family Injection Compression Hansfer Casting Cold Molding Coating Structural Foam Extrusion Laminating Sheet Forming RP Molding FRP Filament Dip and Slush Blow Rotational... 

Fig. 27. Schematic of molten polymer flow during injection molding into a cold mold...

In cold molding, the compound is compacted in a mold at around room temperature. The compressing operation is similar to that employed in the production of KBr pellets from powdered KBr. The compound generally contains a lot of filler and binder. The compacted material is removed from the mold and placed in an oven where it becomes cross-linked. Ceramic materials are often produced using cold molding. 

Castings are typically produced by pouring liquid into a relatively cold mold and allowing solidification to take place. Heat is removed from the solidifying material by conduction out through the mold. The classic grain structure obtained after this type of solidification is illustrated in Fig. 22.5. 

Molded flexible foam products are becoming more popular. The bulk of the molded flexible urethane foam is employed in the transportation industry, where it is highly suitable for die manufacture of seat cushions, back cushions, and bucket-seat padding. TDl prepolymers were used in flexible foam molding in conjunction with polyether polyols. The need for heat curing has been eliminated by the development of cold-molded or high resiliency foams. 

Rotational Casting. Like rotomolding, the plastisol is poured into a cold mold, which is rotated and heated to gel the plastisol onto the walls of the mold. It is then heated to fuse, cooled to solidify, opened, and the product removed. Typical products are volley balls, basketballs, dolls, and auto parts. 

Cold Press Molding. Occasionally the mix may be placed in a cold mold and pressed at about 345 kPa (50 psi). The cure cycle is considerably longer. 

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