Modified compression molding

Injection-compression molding See in this chapter INJECTION MOLDING, Modified IM Technique, Injection-compression molding. 

After synthesis, the modified carborane-siloxane gums were fabricated into shaped components using standard siloxane vulcanization and fabrication technology. Di-chlorobenzyl peroxide (1% by wt) was used as the cross-linking agent and mixed into the polymer formed in scheme 7. Shaped rubber components were readily prepared by compression molding operations at 70°C. Postcure operations were typically at 120°C for 24 hours. 

The thermal stability of poly(vinyl chloride) is improved greatly by the in situ polymerization of butadiene or by reaction with preformed cis-1,4-polybutadiene using a diethyl-aluminum chloride-cobalt compound catalyst system. The improved thermal stability at 3-10% add-on is manifested by greatly reduced discoloration when the modified poly-(vinyl chloride) is compression molded at 200°C in air in the absence of a stabilizer, hydrogen chloride evolution at 180°C is retarded, and the temperature for the onset of HCl evolution and the peak decomposition temperature (DTA) increase, i.e. 260°-280°C and 290°-325° C, respectively, compared with 240°-260°C and 260°-280°C for the unmodified homopolymer, in the absence of stabilizer. The grafting reaction may be carried out on suspension, emulsion, or bulk polymerized poly(vinyl chloride) with little or no change in the glass transition temperature. 

Discoloration. When PVC, free of plasticizer or stabilizer, is compression molded in air at 200°C under adequate pressure (c.g., 500-6000 psig), thermal degradation results in discoloration to a pink to brown colored film. When the modified PVC containing as little as 3% of grafted cis-1,4-polybutadiene was pressed under the same conditions, the resultant film was essentially colorless or no more than faintly discolored. 

The additive was added gradually to the polymer fused on a two-roll mill at 170°-174°C. After addition, polymer sheets were taken off the mill and put back on the mill endwise. Several such passes were made until the sample was thoroughly mixed. The specimen was removed from the mill in thin sheets and, while hot, cut into small pieces. The polymer was compression molded at 700 p.s.i.g. and a temperature of ca. 155°C. into a 6 X 6-inch sheet of about 0.045-inch thickness. This sheet was cut into the 5 X 1/2 X 0.045-inch specimens for burning in the modified D635 test. The sample was initially evaluated with 25% additive. If the compound was effective, lower concentrations were used until the additive would not confer fire retardant activity, or until the supply of additive was exhausted. With poly (methyl methacrylate), PMMA, cast samples also were prepared. 

The mold can be modified to meet certain different shapes. The molding can be made either by withdrawing cores or by special press motions that partially open the mold halves (such as the compression molds used in coining to provide 2-D action 3-D mold actions are also used). The degree of foam density, wall thickness, and surface finish depends on the foam mixture (constituents and amounts). The machine controls the time cycle and the mold action required. 

Fig. 13 Influence of the cooling rate on the impact performance of /S-modified PP (MFR 0.3 dg min-1). The specimens were compression molded and tested at 1.5 ms-1. The arrows indicate the temperature at which the ductile-brittle transition occurred...

We have tested the following polymers polycarbonate (PC), poly-carbonate/4% polyethylene blend (PC/PE), poly (ethylene terephthal-ate) (PET), ABS, and impact modified polystyrene (HIPS). All materials except PC were compression molded into nominal Vs-inch sheets. The PC used was an Vs-inch extruded sheet heat-treated in a manner previously described (22). These PC specimens were considered to be... 

Table 15.5 Solubility properties of SMA-AN impact modified terpolymers after compression molding...

However, they can also be transfer or compression molded, solid state formed or thermoformed. PC is the matrix phase in most of these blends. The impact modifier can be PE, ABS or acrylic copolymer, e.g., MBS. The blends show good processability, heat resistance, ductility, HDT, high modulus, impact, tensile and flexural strength over a wide temperature range, good adhesion, solvent, chemical, and UV resistance. They can be painted, hot stamped, metallized and plated. Some blends (containing PB as impact modifier) may have poor weatherability. The blends are mainly used in the automotive industry. 

PP/EPDM Blends To improve impact properties of PP, the resin is usually modified by incorporation of an elastomer. Since the performance depends on morphology, radiation crosslinking was used in its stabilization [van Gisbergen et al., 1989a] (Table 11.9). The blends were made either in a two-roll miU, at 185°C, then compression molded into 1-mm-thick sheets, or in a co-rotating twin-screw extruder, then pelletized. The irradiations (100 kGy) were done using a 3-MeV electron accelerator. Irradiated and non-irradiated pellets were injection-molded. Eor the DSC measurements, the samples were melted at 200°C, quenched to 110°C, and then heated at a rate of 10°C/min. 

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