Moulding Products

Different kinds of castings and moulded products or forged materials etc. 

Uses reported include motor housings for portable fans, food blender bases, tape storage housings, tough, clear toys, injection blow moulded products and thermoformed packages. 

Another area which is of considerable interest is the development of rotationally moulded products. These mouldings include air ducting housing and a 700-litre frozen food container, both of which are greater than 20 kg in weight. 

Such conditions are particularly prevalent in the car industry where moulded foam is used for chair backs, chair seats, head restraints and knee strips. The furniture industry also widely uses moulded products. 

The RIM process was originally developed for the car industry for the production of bumpers, front ends, rear ends, fascia panels and instrument housings. At least one mass-produced American car has RIM body panels. For many of these products, however, a number of injection moulding products are competitive, including such diverse materials as polycarbonate/PBT blends and polypropylene/EPDM blends. In the shoe industry the RIM process has been used to make soling materials from semi-flexible polyurethane foams. 

At one time the small fragments of amber produced during the fabrication and machining operations were used to produce varnishes. In 1880 they were first used in the production of Ambroid. This is made by pressing the fragments in a hydraulic press at temperatures somewhat above 160°C. The moulded product has a close resemblance to amber. A form of extrusion has also been used to produce amber rods for subsequent conversion into pipe and cigarette-holder mouthpieces. 

One of the major innovations in recent years is the use of pulsed pressure through the gates to introduce and control the orientation of the structure (or fillers) in injection moulded products. A special manifold is attached to the machine nozzle as illustrated in Fig. 4.46. This diagram relates to the double live feed of melt although up to four pistons, capable of applying oscillating pressure may be used. 

The study on commercial HDPE samples could not provide a correlation of the izod impact test with the field performance test, i.e., drop impact resistance on moulded products [113]. It was found that the sample of highest density and lowest izod impact strength passed the drop impact test, but other samples of lower density and higher izod impact strength could not withstand shock loading by drop impact and failed in brittle manner. This may be due to the fact that velocities and modes of loading vary widely in different impact tests. It has been reported that even the qualitative agreement between the different impact tests is poor because the test bars and moulded products often have different orientation characteristics, particularly near the surface [115]. 

Additives are needed not only to make resins processable and to improve the properties of the moulded product during use. As the scope of plastics has increased, so has the range of additives for better mechanical properties, resistance to heat, light and weathering, flame retardancy, electrical conductivity, etc. The demands of packaging have produced additive systems to aid the efficient production of film, and have developed the general need for additives which are safe for use in packaging and other applications where there is direct contact with food or drink. 

A strip of metal used to confine the edges of moulded products, e.g., belting, during press vulcanisation. 

A shallow depression on the otherwise smooth surface of a moulded product, generally due to air trapping. 

A term applied to a moulded product which has failed to fill out the pattern details, showing rounded edges and porosity, either surface and/or internal. It does not necessarily mean that insufficient weight of compound has been used. Light Ageing... 

Many moulded products can be separated from their excess moulding scrap by use of scissors, cryogenic deflashing or buffing. The latter process has to be carried out with caution for those products which are bonded to metal substrates, because excessive generation of heat will result in loss of the bond integrity and product failure. 

In-mould labelling (IML) used for injection-moulded products and blow-moulded bottles is an alternative to self-adhesive or heat-transfer decoration, eliminating a finishing step. 

Bis(bromomethyl)propane-l,3-diol is a reactive flame retardant that is used primarily in unsaturated polyester resins for moulded products and in rigid polyurethane... 

As a rule-of-thumb, for every 10°C rise in temperature the cure time is reduced half. The heating medium in press curing of moulded products is either steam or electricity. 

ASTM D575105 does not primarily recommend the generation of a stress/strain curve but details two methods - force at given deflection and deflection at given force. The test piece is a cylinder 28.6 0.1 mm diameter and 12.5 0.5 mm thick from which all moulded surface layers have been removed. The removal of moulded surfaces is presumably to eliminate skin effects, although such effects, if significant, would be present in a moulded product and one would expect to test in the same condition. 

M. Bulters and A. Schepens, The Origin of the Surface Defect Slip-stick on Injection Moulded Products, Proc. Annu. Meet., American Institute of Chemical Engineering, Los Angeles, CA, 2000. 

PLA is finding a wide range of uses, both as a moulded product for the packaging sector, as a film for wrapping and lamination applications, as a fibre fill (pillows/duvets etc.), as a foam, and as a spun textile fibre. Lactic acid produced from microbial fermentation of starch also has many other industrial opportunities, as it is a useful base chemical feedstock for a range of applications. Lactic acid can be chemically converted to propylene glycol, the base for a range of... 

Plastic film, bags, coating for paper Moulded products, containers, crates Illuminated signs, hospital incubators, car lights, etc. 

In 2005, Japanese company Kaneka developed the first beads-process, foamed resin moulded product, which is based on polylactic acid. The new KanePearl product has the strength and shock-absorbing properties of existing beads-process, foamed polystyrene products. 

Unitika Textiles in Japan has also developed a technology to manufacture foam-moulded products with good heat resistance using PLA. 

Packaging, including foodservice, is easily the largest end use market for PLA with 70% of total consumption in 2005. Textile fibres account for an estimated 23% of total volumes. Other applications, with just 7% of total volumes, include speciality cards and sheet, agricultural products and a wide range of injection moulded products. 

Bomatic, Inc. has been a producer of plastic bottles and containers since 1969. The company serves the personal care, automotive, pharmaceutical, medical, lawn and garden, food, household cleaners, and industrial chemicals markets. Production capabilities include extrusion blow moulding and injection moulding products made from HDPE, PVC, LDPE, PET, PETG, polycarbonate, polystyrene, polypropylene, and polyurethane. 

Fitt, Italy s largest producer of PVC extruded and injection moulded products, recently presented a process for treating and using recycled post-use plastics from cables in the manufacture of pipe and moulded products. Tarkett Sommer, one of the world s largest PVC flooring manufacturers, processes almost 100,000 t/y of PVC at seven plants in Europe and is recycling about 8.4 tonnes of waste material a month. 

Anisotropy of mechanical properties at the increase of filler concentration [70, 78] rises significantly in the items produced from mineral media-filled thermoplasts. When a mineral filler is replaced for a mineralorganic, the dfect of mechanical anisotropy increase fades considerably [18]. At the same time cp values, durability of cold seal moulded products, made of kerogenes is higher than in products of mineral materials-filled compositions [18]. 

IM is an efficient and highly versatile process, capable of rapid production of complex components within relatively tightly-controlled dimensional tolerances. A number of variants of the conventional IM process have been developed either to address various processing problems or to mould products of increased complexity. 

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