Thermoforming Thermoset Plastic

There are many ways in which foams can be processed and used as slabs, blocks, boards, sheets, molded shapes, sprayed coatings, extruded profiles, foamed in place in existing cavities, in which the liquid material is poured and allowed to foam, and as structural foams (Chapter 6, STRUCTURAL FOAM). Conventional equipment such as extruders, injection, or compression machines is used. However specially designed machines are available to just produce foamed products. 

The foaming methods vary widely. One approach is to whip air into suspension or a solution of the plastic, which is then hardened by heat curing. A second is to dissolve a gas 

Property ASTM Test Phenolics Foamedin Syntactic Place Castable Polyvinyl Chloride Rigid Closed Cell Phenylene Oxide Foamable Resin Polycarbonate Polystyrene Medium-Density Foam Polystyrene Molded Extruded Polyurethane Rigid Closed Cell 

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The chassis is made from a 1/4 in. sheet of either ABS or TPO vacuum formed into a tub and reinforced with reinforced pultruded glass fiber-TS polyester plastic tubing. The hood and other products are being made from a 20 mm thick sandwich of thermo-formed PPO-alloy skins, glass fabric infused with thermosetting vinyl ester, and a urethane foam core. The bumper and front fascia is thermoformed from a polyolefin elastomer sheet with an UV-resistant cap layer of DuPont s Tediar PVF film. The dash and... 

Development of a glossy, aesthetic and unpainted roof module on the Smart Roadster by DaimlerChrysler AG s Smart. The two-piece, removable roof, built by ArvinMeritor, is surfaced with a thermoformable three-layer film (Lexan by GE Plastics) that can be co-moulded with either thermoplastic or thermoset substrates. The film exhibits 95% gloss retention after the equivalent of 10 years of Florida sun exposure. Weight saving is 50% versus a painted steel roof system. 

Process can include heating that is usually well below the plastic s melt or thermoforming temperature. Thermoset (TS) plastics such as B-stage can be used (Chapter 15). The main difference between metal and plastic forming is the time dependency or spring-back, or recovery... 

This is an extension of the cold forming process. It uses thermoformed B-stage thermoset reinforced plastic (RP) skin to improve surface and other characteristics to a cold molded thermoplastic. The mold is closed and the fast, room temperature curing RP plastic system hardens. The finished product has the smooth TP-formed sheet. 

Temperature influence 28 Thermoforming 11, 24 Thermoplastics 5 Thermosets 5 Thickness, plastic 35 uniformity 35 Threads 60 inside 81 outside 79 pitch 83... 

Foams are versatile both in their applications and in the way in which the materials are made. These include the production of various shapes by casting, extruding, injection molding, thermoforming, and reaction injection molding. Foam versatihty also includes the fact that any plastic material, thermoplastic or thermoset, may be produced in cellular form. 

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