Composites injection molding

The composites injection molded at the lower temperature (180°C) did not exhibit any skin/core effect, but rather contained fibers throughout. 

According to the composite theory, tensile modulus of fiber reinforced composites can be calculated by knowing the mechanical constants of the components, their volume fraction, the fiber aspect ratio, and orientation. But in the case of in situ composites injection molded, the TLCP fibrils are developed during the processing and are still embedded in the matrix. Their modulus cannot be directly measured. To overcome this problem, a calculation procedure was developed to estimate the tensile modulus of the dispersed fibers and droplets as following. 

Fig. 18.5 Fiber length distribution in rayon-PP composite injection molded test bar with 25% fiber content, 3 mm cut length during processing...

P. Gerard, J. Raine and J. Pabiot, Characterization of fiber and molecular orientations and their interaction in composite injection molding. Journal of Reinforced Plastics and Composites, 17, 922-934 (1998). 

Finite element analysis of the seals by the University of Michigan resulted in replacement of the steel pressure plates with plates made of a reinforced nylon composite. Injection molded with ribs, the redesigned pressure plates distribute torque more evenly, while providing higher dielectric strength and improved corrosion resistance. 

Suspension Polymers. Methacrylate suspension polymers are characterized by thek composition and particle-size distribution. Screen analysis is the most common method for determining particle size. Melt-flow characteristics under various conditions of heat and pressure are important for polymers intended for extmsion or injection molding appHcations. Suspension polymers prepared as ion-exchange resins are characterized by thek ion-exchange capacity, density (apparent and wet), solvent sweUing, moisture holding capacity, porosity, and salt-spHtting characteristics (105). 

Composites. The history of phenoHc resin composites goes back to the early development of phenoHc materials, when wood flour, minerals, and colorants were combined with phenoHc resins to produce mol ding compounds. In later appHcations, resin varnishes were developed for kraft paper and textile fabrics to make decorative and industrial laminates. Although phenoHcs have been well characterized in glass-reinforced composites, new developments continue in this area, such as new systems for Hquid-injection molding (LIM) and sheet-molding compounds (SMC). More compHcated composite systems are based on aramid and graphite fibers. 

The use of TAG as a curing agent continues to grow for polyolefins and olefin copolymer plastics and mbbers. Examples include polyethylene (109), chlorosulfonated polyethylene (110), polypropylene (111), ethylene—vinyl acetate (112), ethylene—propylene copolymer (113), acrylonitrile copolymers (114), and methylstyrene polymers (115). In ethylene—propylene copolymer mbber compositions. TAG has been used for injection molding of fenders (116). Unsaturated elastomers, such as EPDM, cross link with TAG by hydrogen abstraction and addition to double bonds in the presence of peroxyketal catalysts (117) (see Elastol rs, synthetic). 

The mechanical properties of the injection molded blends and composites are shown in Table 3. 

The TLCP used was a widely investigated one, Vectra A950, manufactured by Hoechst-Celanese. The PC was produced by Enichem under the tradename Sinvet 303. Table 3 lists the main properties of these materials according to the manufacturers. The materials were dried in a vacuum oven at 120°C for 4 h before processing. Prior to injection molding of the composite samples, two components were melt mixed by a ZSK, W P, Stuttgart, extruder with a constant weight ratio of PC-TLCP = 80 20 [23]. 

Table 4 Processing Condition and Mechanical Properties of PC-TLCP Composite Samples Injection Molded...

The polymers studied and the experimental procedure were described in the last section. The samples were made of the same PC-TLCP composite and the pure TLCP Vectra A950, respectively. To study the influence of sample forms and geometries on mechanical constants, plate samples (80 x 80 x 2 mm-) were also injection molded with a film gate. Tensile samples were then cut from the plate in the longitudinal (//) and transverse... 

F. R. Jones, Reinforced Reaction Injection Molding, Handbook of Polymer Fibre Composites, (F. R. James, ed.). Polymer Science and Technology Science, New York (1994). 

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