- Why can colors vary lot to lot
A dye lot is a record taken during manufacturing ensuring the products received coloration in the same vat at the same time. Paint and dye manufacturers assign each lot a unique identification number and stamp it on the label before shipping. Slight differences in temperature, dyeing time, and other factors can result in different shades of the same color between different dye lots of otherwise identical production. Although elements of a dye lot number kept by internal business record keeping, retail yarn and paint consumers have an interest in ensuring that they purchase a given color from identical dye lots.
PRL Resins has expertise of over 40 years perfecting their products, service and processes. They hold the go-to authority reputation regarding the sensitive nature of products madeof resins, solvents and other industrial surfaces.
- Resin holds together the pigment in suspension, provides surface adhesion and determines the quality and durability.
- The pigment is in a powder form much like concrete, and the average aftermarket automobile paint system includes about 100 colors or toners to mix formulas, including metallic and pearl colors.
- The solvent provides transferability, as without solvent the paint would be too thick to transfer between containers.
Theory vs Chemical Reactions
The paint is mixed to exact specifications and all painting performed from that lot of paint will be exactly the same even after sunlight, drying and ultraviolet exposure. However, if the same formula is followed at another temperature or humidity on another day, that lot of paint can be a different shade and sometimes in some of the related colors such as blue-green, it can be another color altogether. Therefore, lots are important and paint compound from one is not going to match perfectly when application is finished.
The same is true in fabrics, and yarn or fabric from the same dye lot is desirable in sufficient amount to complete an article of clothing.
Modern Technical Controls of PRL Resins
PRL Resins has conquered most inconsistency problems with expert handling of their resin that goes beyond that found in any other manufacturing company, and with their high UL certification. The industrial compound ingredients that permit
PRL Resins to manufacture products with truer color matches include:
- UV stability
- easy release by mold releases
- other stability additives
- Impact Modifiers
- Flame Retardants
- Flow Enhancers
- Reinforcing Agents-
- Glass fibers
- Mineral fillers
Revolutionary Data Color Spectrophotometer
Merging SPC with their integrated statistical process control ensures PRL Resins of precise color matching with their custom color control.
Precision color matching:
The continued reinvestment by PRL Resins back into their plastic resin technology, together with their staff of experienced color lab specialists, ensure precise color matching. A Data Color Spectrophotometer with integrated statistical process control SPC gives exact color matching capabilities and ensures lot-to-lot color consistency.This SPC control makes PRL a go-to authority in color and lot consistency. It provides them with expertise to warranty their products fully and offer complete service support to their clients.
- August 28, 2018
- Polymer Resources Blog
- Why the light source effects color
Color provides an emotional impact and is sometimes synonymous with a brand. Having the precise color match for your product is a quality that consumers will rely on and expect. However, different light sources can adjust the perceived color of polymers and resins, which you need to take into consideration when manufacturing and displaying your products.
The polymer’s molecular structure dictates how it processes light emissions. For example, crystalline resins have a semi-opaque look because of the mixture of their ordered and disordered domains. These characteristics cause the crystalline resins like PP to bend light differently. In comparison, non-crystalline resins are usually comprised of disordered domains, so this causes the light to pass straight through them, causing their transparency.
Another characteristic that has a significant impact on how much light influences a particular resin is its melting points. For example, crystalline resins have a high melting point, requiring much more heat before they alter in appearance. To maintain their appearance, inorganic pigments or other materials may be used that provide stability even at higher temperatures. Not using heat-stable materials can cause there to be light and dark streaks in the resin.
When polymers contain cross-linked rubber particles, their appearance may be whiter in appearance. This is the case with such polymers as acrylic, HIPS and ABS. Rubber alters the way that light passes through the resin once it is toughened. If two different color coatings have the same chemical composition, they will match under any light source.
Another component that affects the color of the resin based on the light source is the angle at which the light bends as it passes through the polymer. Resins that have a combination of different refractive indices can be mixed together, which causes the light to not have a single path to go through. This causes the resin to have a more opaque quality to it.
Color changes as it is observed under two different light sources when they have different energy distributions. Even if the resin appears to be the same color due to the same refractive index, the color will be observed differently if the energy distribution is different between the two samples due to a different light source.
Color Matching Tips
Because each light source can affect the color of a polymer, it is important for you to specify the light source in which you plan the resin to be viewed. This will help ensure precise color matching. Here are a few tips to ensure your color will match and that you are satisfied with your experience:
- Specify if you need a color match with more than one light source.
- Ask about any additional costs associated with manufacturing a polymer with different colorants due to varying light sources
- Consider the color match’s tolerance under different light sources
- Specify the type of spectrophotometer that you wish to use as this tool will help provide the basis for the color match.
- August 1, 2018
- Polymer Resources Blog
- The advantages to the customer of multiple warehouses
There are many techniques and theories when it comes to warehousing. Companies can choose between operating between single centrally located warehouses and operating multiple warehouses throughout a region or a country. In multiple warehousing systems, companies spread out to cover territories and be easily accessible to customers. It offers many benefits as compared to single centrally located warehouse systems. There is plenty of debate regarding which is the most efficient and effective. Ultimately, it all comes down to the satisfaction of customers. Depending on the customer satisfaction, it is more appropriate to have multiple warehouses.
Imagine a customer trying to get a product to the middle of Texas when there is only one single located warehouse in New York. While the product would eventually get there, would you lose anything by having it take long? When you have multiple warehouses, there are clear advantages that make you reliable to customers in the long run. From saving on transportation costs to making clients happy, the use of multiple warehouse system just makes sense.
Here are the advantages of having multiple warehouses:
- Quick delivery: with multiple warehouses, delivery time can be cut down pretty dramatically, meaning that you can move more products at a quicker pace. Instead of customers waiting for products to arrive from one single centrally located warehouse, their orders will be shipped quickly from various warehouses, meaning their purchased products arrive quickly.
- Low transportation costs: because products will spread out over a larger area when you have multiple warehouses, the cost of delivering purchased products significantly decreases as warehouses are in the vicinity of customers.
- Easy accessibility: instead of having your products in one place, they will be in multiple places, meaning that if a customer needs a product, the entire process becomes much easier. Having your products spread out means having easy access to multiple warehouses rather than one centrally located warehouse.
Other advantages of multiple warehouses are:
- Elimination of middlemen in between manufacturers and ultimate consumers.
- They avail the advantages of bulk purchasing.
- Uniformity of prices and quality of products sold is maintained at all warehouses.
- If one warehouse has short supplies, then it can be immediately replenished from another warehouse so that customers can easily access products.
- There are low operating costs hence prices are not increased to cater for operations.
- There are flexibilities of operation in such warehouse systems.
- If one warehouse is closed, customers can still access products in other warehouses as compared to single centrally located warehouses where if closed, there are no more operations.
- July 1, 2018
- Polymer Resources Blog
- What is a Data color Spectophotometer and why do I care
Serious investment in a Data Color Spectrophotometer is required to be a major force in the plastic and resin technology field. By equipping our production facilities with the latest Data Color Spectrophotometer technology, Polymer Resources’s color lab specialists are able to engineer precise consistency between lots. Accurate color matching is essential for establishing brands, creating consistent products and taking precise samplings of existing materials. No matter the scope of the project, our specialists are capable of dealing with all types of color matching – even gloss and fluorescent material!
Dye mills and colorant manufacturers agree that Data Color Spectrophotometer products are superior in their accuracy and consistency. By deploying this technology, Polymer Resources is able to work with highly precise and close-tolerant specifications. Our use of high resolution color management allows us to produce both short and long-term reliability while our highly experienced staff guides the plastic and resin manufacturing process.
Spectrophotometry is a vital aspect of skilled plastic work. By analyzing the reflective capacity of a material as well as its diffusivity, we can accurately reproduce any sample or mockup in a sizable scale. Our cutting edge use of Data Color Spectrophotometer technology lets us know exactly what materials are present in a lot and accurately reproduce it with production-level quality. Our double beam Data Color Spectrophotometer technology is highly accurate, using both a reference sample as well as your sample to guarantee precision engineering.
Regular diagnostic testing is essential when producing large amounts of product, and our Data Color Spectrophotometer technology is able to periodically check samplings of a lot to ensure consistency throughout. Integrated with Datacolor TOOLS, we are able to analyze and convey quality control results for our clients. Quality control information can be easily shared between members of our supply chain, making sure only perfect results pass through our gates.
Our exclusive use of industry leading and stable technology requires us to make use of very little calibration, causing our turn times to be significantly faster than less adept companies. Our lead times, among the lowest in the industry, result in shipping custom colors within 4 weeks and standard colors within 2 weeks. With regional warehouses throughout the nation, stock colors can be quickly delivered to you with little delay.
When you want a quality product, Polymer Resources employs only the best people and Data Color Spectrophotometer technology to get the job done. Celebrating over 40 years of success, we have the track record to inspire confidence and proudly guarantee accurate custom color matching for our all our cherished clients.
- June 1, 2018
- Polymer Resources Blog
- Polyetherimide sheet – Performance Characteristics and Applications
Polyetherimide sheets (PEI) guarantees exceptional fire resistance along with excellent mechanical and thermal properties. The amorphous Polyetherimide sheets are suitable for high temperature applications. With properties like low levels of smoke evolution during combustion and very low flammability, they are widely used in electrical and electronic insulators. It can also resist a wide range of chemicals and offers good resistance to UV and gamma radiation.
There are several companies which utilizes the finest Polyetherimide sheets to custom fabricate components which needs long term mechanical strength and rigidity at elevated temperatures. Available either in transparent or opaque colors along with glass filled grades depending on the requirements, PEI exhibits higher levels of heat resistance, dielectric strength, chemical resistance and many more properties.
Custom sizes and colors of PEI sheets are available on request. So, what are the major performance characteristics of Polyetherimide sheets?
- High mechanical strength and stiffness
- Higher levels of dielectric strength
- Excellent thermoforming properties
- Resistance to hydrolysis during exposure to steam and hot water
- Able to withstand repeated sterilization cycles
- Excellent resistance to high energy radiation like UV and gamma
- Excellent for food industry as it is physiologically inert
Because of the above mechanical, thermal and electrical properties, Polyetherimide sheets are widely used in the following applications
- Electrical insulation parts
- Chip test sockets
- Medical instruments
- Scientific equipments
- Electrical connectors
- Semiconductor components
Sheets and rods of Polyetherimide (PEI) are usually available in dark and glass filled formulations. It can easily maintain its strength at elevated temperatures in the range of 200 degree centigrade. For medical applications which require repeated sterilization cycles, Polyetherimide sheets are most suitable as this uniquely balanced thermoplastic can exhibit excellent mechanical properties and heat resistance. The easy to process thermoplastic material allows industries the flexibility in plastic injection molding and manufacturing.
Low moisture absorption and excellent creep resistance allows Polyetherimide sheets to possess amazing dimensional stability. When compared to other amorphous thermoplastics, the Polyetherimide resins show better resistance to stress and cracking in extremely demanding and challenging conditions. One of the key features of PEI sheets is to retain its properties even at high temperatures. Its resistance to mineral acids is simply outstanding, however it can be attacked by use of strong bases and partially halogenated solvents such as methylene chloride and trichloroethane.
Polyetherimide (PEI) is extruded to produce film, sheets, coated wire and profiles. Using solvent casting techniques, the thickness of PEI film can be around 0.25 mil. Major competitors of PEI sheets include polysulfones, polyketones, and polyphenylene sulfides.
- May 1, 2018
- Polymer Resources Blog
- A Practical Guide to choosing the Best Engineering Thermoplastics
With a growing demand for plastic materials in different applications, engineering thermoplastics are developed to offer high performance in heat resistance, fire retardancy, mechanical strength or chemical resistance. Generally, engineering thermoplastics are known to exhibit heat resistance at high temperatures beyond 100 degree Celsius and also offers good flame retardant properties.
Different varieties of engineering thermoplastics can be created by blending two or more resins depending on the required properties. Thermoplastics are known to provide a cost effective and corrosion resistant alternative to different types of metals in various applications. A wide range of Engineering Thermoplastics are available in sheets, plates, tubes and rods which offers myriad advantages over metallic materials and also offers excellent mechanical and thermal properties.
As a production material, Engineering thermoplastics show reduction in weight, provide electrical and thermal insulation, offers great mechanical strength, durability, superior corrosion and chemical resistance, and ease of processing. The selection of the right set of engineering thermoplastics is an important decision and definitely a daunting task. It is important to consider the application requirements and choose engineering thermoplastics accordingly.
A few common types of Engineering plastics and their general uses are discussed below. The below information will help in your search for the perfect engineering thermoplastics for your application.
- ABS Sheets – They are available in a wide range of color and texture finishes and offers a lot of versatility.
- Polyethylene – Different variations are available in the market which are tailored to suit specific market requirements.
- Acetal & Delrin sheets are considered as one of the strongest among all engineered thermoplastics.
- Nylon -With their excellent properties and use in various applications, it is one of the most popular engineering plastics.
- Polycarbonate – With a high heat resistance, it also offers chemical and water resistance.
- Polypropylene – For applications exposed to cold temperature, PPC and PPH grades are highly preferred.
- PTFE – It offers unrivalled chemical, thermal and electrical performance.
Additives can modify the properties of engineering thermoplastics which means that addition of fiber makes the thermoplastic strong and stiff, whereas adding plasticizers makes it more flexible. Use of anti-oxidants would make thermoplastics stable under high temperatures, whereas addition of lubricants makes it easier to mold.
With repeating units of monomers, Engineered thermoplastics are made up of long polymer chains. Various fillers from minerals to fibers can be added for strength, impact, and other performance enhancements like thermal conductivity, electrostatic dissipation etc. With professional cutting services, companies have been able to ensure high quality finishes and a quick turnaround time.
- April 1, 2018
- Polymer Resources Blog
- Nylon 66 Polymer – Step Reaction Polymerization
Nylon-66 is a polyamide fibre which is manufactured by a process that involves step growth polymerization and condensation polymerization. The generic term used to define long chain synthetic polyamides is Nylon. One of the key members from the group of poly-condensation products of acids and diamines, Nylon-66 has great abrasion resistance, strength andresistance towards heat, water and chemicals.
When compared with Nylon 6, Nylon-66 is a superior version due to its higher melting point, greater dimensional stability and a more compact molecular structure. With a guarantee of excellent performance in high speed spinning processes, it also has good UV light-fastness and dye wash fastness.
There are different ways of referring to Nylon-66 as Nylon 6-6, Nylon 6,6 etc. The Nylon 66 polymer is made of hexamethylenediamine and adipic acid which provides Nylon 66, a total of 12 carbon atoms in each repeating unit.
Availability of Nylon 66
Easily available in both sheet and rod form, Nylon 66 has a wide range of applications. Generally the rods are available from 4mm-200mm diameter and the sheets are from 5mm thick to 100 mm thick.
The ingredients i.e. Hexamethylenediamine and adipic acid are combined with water in a reactor. The outcome of this process is the nylon salt which is sent for evaporation which removes any excess water. The nylon salt is then passed through a reaction vessel where a continuous polymerization process makes molten Nylon 6,6. The molten nylon is then passed through a spinning process, with Nylon-66 extruded and sent via spinneret. Once the nylon is air cooled to form filaments.
Nylon-66 can operate at temperatures exceeding 100 °C, where the maximum limit is 160 °C and generally allowed only for short term applications.
Probably, one of the most important and popular engineering plastic, it can be utilized for a wide range of applications like bearings, gears, pulleys, screws, bushes etc.
Around 55 years back, Remington Nylon 66 took polymers to a new level with the introduction of world’s first mass produced rifle made from something other than wood.
The long molecular chains of Nylon 66 results in higher number of hydrogen bonds which also makes it extremely resilient. Being an amorphous solid, it is slightly soluble in boiling water and has large elastic properties. It offers immaculate dimensional stability, high melting point and excellent abrasion resistance. With the use of reinforcements, the physical strength of Nylon-66 can be improved multiple times. Few popular applications of Nylon includes carpet fibres, swimwear, parachutes, tyres, ropes and air bags etc.
- March 1, 2018
- Polymer Resources Blog
- Polycarbonate Panels – Various Applications and Benefits
Composed of thermoplastic polymers, Polycarbonate panels are usually found in several industrial applications. Polycarbonate is a polymer which includes numerous identical units of bisphenol A which are interlinked by carbonate. This type of polymer liquefies when heated and converts into a glassy state when cooled. Polycarbonate panels offer high impact resistance and protection from cracking, breaking or chipping. These panels are available in different sizes, shapes and colors.
The polycarbonate panels are reasonably lightweight and usually available in single, double and triple wall panels. To achieve the desired shape and finish, the polymer is melted and forced through a die. Polycarbonate panels are processed using the following main processes like injection molding and extrusion.
- Injection molding: Initially the polymer is heated, melted and then pressed into a mold, so that it can take the desired shape of the mold. Usually used to manufacture single end products, injection molding is highly effective.
- Extrusion: The polycarbonate is melted and pressed through an orifice which allows the molten polymer to take the shape of the die. Most manufacturers use this process to produce large sheets, pipes and profiles.
There are several benefits associated with the use of polycarbonate panels which are usually used in glazing applications.
- High durability and strength: The polycarbonate panels are used in a wide range of industrial applications. The high durability features of the panels allow it to withstand harsh climatic conditions, resistance to chemicals and abrasion.
- Highly cost-effective: There are several factors which decide cost effectiveness like installation cost, maintenance cost and the aspect of time. Polycarbonate panels are generally expensive, so what makes them cost effective? They offer longevity which means that they maintain their condition and shape for several years, thereby providing complete value for money.
- Greenhouse construction: Polycarbonate panels are in great demand for greenhouse construction. This is because, the panels fulfill almost all requirements of any greenhouse glazing panel. By enhancing light diffusion and guaranteeing longevity, polycarbonate panels are popular among farmers.
- Effective design: The polycarbonate panels are available in different designs and finishes. They tend to offer a mixed variety of several properties like energy saving, moderate light transmission, insulation properties, longevity, etc.
In case of residential buildings, these panels are usually used for awnings and overhead shades because they provide protection from harmful UV rays and easily withstands strong forces. In comparison to other type of panels made with glass or plastic, the polycarbonate panels are extremely lightweight which translates to lower transport and labor costs.
- February 1, 2018
- Polymer Resources Blog
- Amorphous Thermoplastics – Characteristics of Non-crystalline materials
Plastics are loaded with macromolecules which are made under the action of heat and pressure such that it can be processed into the desired shape. There are two broad classifications of a thermoplastic i.e. amorphous thermoplastics and semi-crystalline thermoplastics. When the thermoplastic is shaped at a temperature over the glass transition temperature Tg, then it is classified as Amorphous Thermoplastics. Whereas, when the temperature is over the melting temperature Tm, it is classified as Semi-crystalline thermoplastics.
Completely amorphous thermoplastics are generally brittle, stiff and quite clear in their unprocessed state. Temperature and pressure can cause the molecular arrangement to change along with the properties of the polymer. Tg or the glass transition temperature is defined as the point when the molecular rotation about single bonds becomes favorable. There are different varieties of Amorphous thermoplastics which includes materials like polystyrene, acrylics, polycarbonate, Acrylonitrile-butadiene styrene and polyvinyl chloride.
The molecules in case of amorphous thermoplastics are entangled in solid state. Most of them are transparent in their natural form, however ABS is an exception. In general, amorphous thermoplastics are known to have lower chemical resistance and lower stiffness and strength when compared with crystalline materials. However, the amorphous thermoplastics have uniform shrinkage rates which means that their shrinkage can be calculated easily.
There are additives and fillers used with both amorphous and semi-crystalline thermoplastics to alter the physical, electrical, thermal and mechanical properties of the base resin. Amorphous thermoplastics can be used in a wide variety of applications because of its diverse range of properties. With state of the art molding machine controls and latest material formulation methods, Polymer Resources guarantees high quality and consistent molded parts.
There are different varieties of crystalline materials which includes Nylon, polypropylene, polyacetal, and thermoplastic polyesters. In case of semi-crystalline thermoplastics, the size of the crystals is larger than the wavelength of visible length, thereby making the materials translucent. Depending on the branching and cooling rate, there are different degrees of crystallinity. Close to 85% of the resins produced are thermoplastics which are further classified as amorphous thermoplastics and crystalline thermoplastics. The amorphous regions of the thermoplastics contributes to the elasticity of the thermoplastic whereas the crystalline regions contribute to the strength and durability of the thermoplastic.
The cost saving opportunities associated with the use of injection moulding technology of thermoplastics need to be ensure proper material usage and cycle time to achieve optimized results. Amorphous thermoplastics exhibit lower mold shrinkage and lower tendency to buckle under pressure when compared with semi-crystalline materials. They lose their strength and rigidity very quickly once above the glass transition temperature Tg. The randomly ordered molecular structure allows amorphous thermoplastics to soften gradually as the temperature increases.
- January 1, 2018
- Polymer Resources Blog
- ABS Resin Plastic – Features, Limitations and Variations
One of the best resins of the styrene family, ABS (Acrylonitrile Butadiene Styrene) is widely used in the automotive industry and in the manufacture of electrical and electronic equipment. The increased utilization of ABS Resin plastic means that there would be substantial volumes of material which would need to be recycled at the end of life of these products. Research studies focused on the impact of reprocessing on the physical and mechanical properties of ABS products have shown minimal impact therefore establishing the benefits of ABS Resin plastic as an easy to recycle material.
ABS is a common thermoplastic resin which guarantees high rigidity, durability, dimensional stability and excellent chemical resistance. The high quality features of ABS resin can be attributed to its composition where it brings in the strength and durability of Acrylonitrile along with the toughness of butadiene rubber. It also allows a wide range of modifications to its composition which allows to improve its impact resistance, heat resistance and toughness.
Some of the most common and well known features of ABS Resin includes:
- Excellent ductility
- High Impact strength
- Extremely tough and rigid
- Dimensional stability
- High tensile strength
- Heat and chemical resistance
- High and low temperature performance
Although there are several benefits associated with the use of ABS Resin, there are certain limitations as well like its poor solvent resistance, poor weather ability and heavy generation of smoke when burnt.
There are huge variations possible with ABS Resin, however the most common variations of ABS material includes General Purpose ABS, High Impact ABS, Low Viscosity ABS, Plate-able ABS, ABS FR and many more. The modifications of its properties is possible with the use of additives, modifiers and reinforcing agents.
ABS plastics are largely used for mechanical purposes and in the automotive industry, however it also boasts good electrical properties which show minimal impact with temperature and humidity changes.
The two most common reprocessing or recycling process used for ABS products include mechanical recycling and solvent based process. Several research studies and experiments have proved that the microstructure of ABS resin is not affected by the recycling process. For painted parts, it is usually recommended to use the solvent based recycling process to ensure minimal butadiene loss.
Known for its medium strength and performance at affordable pricing, ABS Resin is commonly used for injection molding applications. The mechanical properties of ABS Resin plastic makes it ideal for drilling, turning, die-cutting and shearing. It also possesses excellent creep resistance, abrasion resistance and electrical properties, thereby making it one of the most widely used resins ever. Because of its great versatility, ABS Resin is used in a wide variety of applications. The three components used in the manufacture of ABS resin are combined by different methods which involves polymerization, combinations and physical mixtures.
- December 1, 2017
- Polymer Resources Blog
- Compounding Resin Productions to Peak with Shale Gas Boom
The plentiful supply of shale gas in North America has prompted the emergence of the US as an important center for worldwide petrochemical production. Thanks to the abundance of cheap shale gas as a feedstock, petrochemical production costs have gone down dramatically. The shale gas boom could potentially result in a surge in compounding resin production.
The increase in natural gas availability due to the shale gas boom has resulted in a plentiful supply of ethylene. This in turn has led to a dramatic increase in polyethylene production via the process of ethylene cracking. Lower polyethylene prices and increased production capacity could potentially have a substantial impact on resin prices.
Opinions vary as to what extent plastics processors stand to gain from the shale gas boom. On the one hand, the reduction in polyethylene production costs ought to be beneficial for plastics processors as their material expenses stand to decrease considerably. However, it is unclear just how far the price of polyethylene could fall. It has been suggested that the price of polyethylene corresponds to the cost of production from crude oil, rather than from natural gas. Furthermore, polyethylene prices are dictated by the inventory of the supplier.
In addition to ethylene, shale gas also contains a large amount of propylene. The new abundance of shale gas therefore has implications for polypropylene production. Most of the benefits the petrochemicals industry has derived from shale gas thus far have come from ethylene cracking. However, recent advances in propylene dehydrogenation (PDH) technology mean that this is expected to change. With resin producers set to begin polypropylene production as early as 2015, the full force of the shale gas boom may soon be felt in the polypropylene sector. While polypropylene prices are unlikely to fall to the extent of polyethylene prices, the increased availability of propylene is expected to result in a less volatile polypropylene market.
The extent to which the shale gas revolution will drive compounding resin production may not yet be fully understood; however, it is clear that these are exciting times for the US petrochemicals industry. The advantage of shale gas is local to North America, and opportunities abound for both domestic business and export.
- November 1, 2017
- Polymer Resources Blog
- Polyurethane Resin Impregnation
In a variety of manufacturing and industrial processes, there’s a need for polyurethane resin impregnation – an easy process of filling porous material using polyurethane resins, as well as making it impervious. The process assists in addressing issues associated with micro porosity in powder-metal parts, metal castings, plastic composites, electronic components, welds, and additional porous substrates – if gone untreated, it might result in poor quality of surface finish and pressure leakage. It brings an immediate necessity of an in-demand resin impregnation technology which will treat any kind of porous issues and improves their potential, while simultaneously ensuring performance that is free of leaks.
Before exploring any further, let us understand more on Polyurethane Resin Impregnation technology. It’s amongst the most typical methods utilized to seal the voids and cavities between the wire windings, which result in improved electrical insulation. Also, the impregnation assists in decreasing vibrations by repairing the wires surroundings the windings. In plain terms, it’s a standard method of avoiding component leakage, and upgrading the surface treatment.
Polyurethane (PU and PUR) polymers, in this approach, are utilized as resin blend in order to seal open pores. There isn’t any secret that it’s a ‘resin of choice’ as it will come to surface coatings, electrical potting compounds, high performance adhesives, and surface sealants. They’re valued for their resin properties. Pressure, vacuum, and temperature include the main parameters utilized in Polyurethane impregnation processing. Make sure you provide maximum attention to the correct viscosity; otherwise incorrect viscosity might lead to stress cracks and incomplete saturation.
Polyurethane impregnation approach possesses numerous benefits. Let us examine look some major advantages of the same:
- Boost in thermal conductivity
- Better electrical insulation with minimal vibrations
- No resin residuals on laminations and shafts
- High bond strength
- Develops a bonding effect upon the lamination
- No presence of bubbles within the resin-winding mass
- Accurate penetration of resin deep inside a variety of existing gaps
The most broadly utilized equipment for Polyurethane Resin Impregnation include vacuum potting, Hot Dipping, Roll Dip, and Trickling. You easily can discover numerous available choices in the marketplace for them. But, what’s important is that you select the proper machine from the proper dealer.
While planning to purchase an impregnation machine, you ought to provide utmost importance to factors such as yield of resin, energy optimization, programmable auto shut down and start, automatic flushing of drippers and pumps, automatic system lubrication, automatic failure diagnostics, ease of operation, low maintenance, low thermal dissipation, and much more. Do not forget to check the manufacturer’s warranty, specifications, and quality prior to making a final purchase.
For more information on this process contact Polymer Resources at 1-800-243-5176.
- October 1, 2017
- Polymer Resources Blog
- Thermoplastic Injection Molding – An Engineer’s Guide
High quality products manufactured with great accuracy, quickly and in large numbers – Thermoplastic injection molding is definitely one of the most popular manufacturing methods. The use of thermoplastic materials has seen an upsurge due to the growing demands of manufacturing quality plastic products for diverse industries.
Thermoplastic, made from polymer resins becomes a homogenized liquid when heated and gets hardened when cooled. The materials used for Injection molding process brings in its own unique features while guaranteeing best performance. Apart from thermoplastic polymers, one can also use thermosetting plastic or Elastomer which provides equally great results with Injection molding.
Advanced injection molding techniques and molds have offered better prospects, reduced costs and better appearance of the end product. There are different types of thermoplastic materials which are used in the molding process like
- ABS – With high impact strength, scratch resistance and durability Acrylonitrile Butadiene Styrene is in great demand for a wide range of applications. ABS is mostly used by the automobile industry for manufacturing radiator grilles, instrument panels, wheel covers and mirror housings. There are several consumer electronic goods like laundry irons, hair dryers, vacuum cleaners and many more which are manufacturing by thermoplastic injection molding process.
- Polypropylene – This type of thermoplastic is generally preferred in industries where one needs high flexibility, lightness, great shape and longevity. Mostly used in the manufacturing and packaging industry because of its good chemical resistance and attractive shape, Polypropylene is used for manufacturing washing machine drums, automotive parts, plumbing equipment etc.
- Acrylic – The hardness of Polymethyl Methacrylate is comparable to Aluminum and it finds great use in the manufacture of lenses, control panels etc. Last few years have seen a growing demand for thermoplastic injection molding manufacturing process.
- Polyethylene – The high density material exhibits diverse characteristics like chemical resistance, high heat distortion temperature and stiffness making it ideal for manufacturing fuel tanks, refrigerator containers, food storage boxes etc.
- Polystyrene – Characterized by high gloss, transparency and high strength, this type of thermoplastic polymer is used for manufacturing products of diverse colors. Ideal for use in packaging and toys industries due to its crystal clear quality. There is a higher impact variety of the same material which is used in the manufacture of toilet seats, refrigerator linings etc.
The thermoplastic injection molding process starts with the addition of pellets to a hopper. Thereafter, the material is passed through a heated barrel where the rotation of the screw initiates a shearing action causing the pellets to melt. The molten plastic is then pushed through the barrel towards the mold. The material is pushed at high pressure such that the mold cavities are completely filled. Once the cooling cycle ends, the mold is opened to release the molded parts manufactured by thermoplastic injection molding process.
There are few subcategories under injection molding process which includes mold labeling, foamed injection molding or gas assisted injection molding etc. Mass production without compromising on quality and price makes thermoplastic injection molding one of the most sought after engineering process of large scale manufacturing. It is important to understand that each of the thermoplastic processing technique is unique and can be tailored to suit your requirements. There are various diverse industries which benefits from the myriad advantages offered by thermoplastic injection molding process like Aerospace industry, Toy manufacturing, Household goods manufacturing, construction and many more.
- September 1, 2017
- Polymer Resources Blog
- Structural Foam Molding – Working with Complicated Designs
For products which require a softer inner core and a hard outer surface, Structural foam molding guarantees tough and reliable wall sections. This type of molding process is generally used for medium to high volume production and produced on injection molding machines where a foaming agent is used to produce thick internal wall sections.
Depending on the processing method and the application, there are wide varieties of Polycarbonate plastic available in the market. There are different blends of Polycarbonate PC like ABS, Polyesters etc. which are normally used in the automotive industry. There are various processing methods associated with Polycarbonate which includes Injection molding, Vacuum forming, Extrusion, Structural foam molding and Blow molding.
Typically used for applications or products where the goal is to reduce the component weight and tension in the material needs to be avoided, Structural foam molding allows the designer to work easily with complicated designs because the material thickness can be varied between 4 and 10 mm, allowing for diverse designs. A high level description of the structural foam molding process includes use of an injecting propellant which creates the material structure with consistent shape and design throughout the product.
Among several advantages associated with Structural foam molding, one of the most interesting aspects is its ability to make lightweight yet extremely durable and strong products. However, one also needs to be aware that the product surface needs to be painted for a better visual appearance. The superior strength to weight ratio and the use of low pressure allows a wide range of flexible and complex designs, thereby making this process extremely popular.
The process involves use of a small amount of chemical blow agent inside the plastic material which makes the internal walls thicker. When the melted plastic gradually enters the mold cavity, foaming would create a plastic wall that solidifies into a great molding wall. This versatile process can be easily used with any thermoplastic which can be injection molded. The large plastic products have a solid skin and a cellular inner structure while keeping the weight lower which makes it a favorite for vehicles, sports equipment and aircraft.
Structural foam molding needs Nitrogen to be injected into the melt before it is injected into the mold. Once the solid wall is created, the core is retracted so that the pressurized gas can expand and create a uniform cellular structure. Used with most thermoplastic materials, the process allows for weight reduction without compromising on its high rigidity features. The molded material doesn’t warp and also there are no sink marks because of the dense skin and rigid core.
The dimensional stability and high impact strength allows for great processing flexibility. The structural foam molding process creates molded parts with a smooth and solid surface on the outside and a foam structure on the inside.
- August 1, 2017
- Polymer Resources Blog