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Thermosetting Plastics Classification Tables
Here’s the thermosetting plastics classification table for the injection mold industry.
Thermosetting Plastics Classification Table |
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Category |
Chemical Name |
Abbr. |
Key Properties |
Typical Applications |
| Phenolic Resins | Phenol-Formaldehyde | PF | High rigidity, heat resistant (150°C), flame retardant, low cost | Electrical switches/outlets, cookware handles, PCB substrates |
| Epoxy Resins | Diglycidyl Ether of Bisphenol-A | EP | High strength (60-85MPa), chemical resistant, excellent adhesion | Carbon fiber composites, electronic encapsulants, floor coatings |
| Unsaturated Polyesters | Orthophthalic/Isophthalic | UP | Room temperature curable, weather resistant | FRP products (boats/tanks), artificial stone, automotive parts |
| Thermoset Polyurethanes | Methylene Diphenyl Diisocyanate | PU | Wide hardness range (Shore A30-D80), abrasion resistant | Rigid foam (refrigerators), flexible foam (cushions), elastomers (tires/seals) |
| Melamine Resins | Melamine-Formaldehyde | MF | Surface hardness (3H pencil), scratch resistant | Tableware, laminate surfaces, decorative panels |
| Silicone Resins | Polymethylsiloxane | SI | Extreme temperature range (-60-250°C), excellent dielectric properties | High-temperature gaskets, LED encapsulation, baby bottle nipples |
| Polyimides | Poly(pyromellitimide) | PI | Exceptional heat resistance (300°C continuous), low dielectric loss | Aerospace components, flexible circuits, high-temp motor insulation |
| Furan Resins | Furfuryl Alcohol-Based | – | Superior acid/alkali resistance (pH1-14) | Chemical tank linings, foundry sand binders |
| DAP Resins | Diallyl Phthalate | DAP | Dimensional stability (±0.1% shrinkage), electrical insulation | Precision electronic connectors, military-grade insulators |
| Polybenzoxazines | Benzoxazine Monomer-Based | PBZ | Near-zero shrinkage (<0.5%), self-extinguishing (halogen-free) | Advanced electronics packaging, spacecraft ablative materials |
Thermosetting Plastics: Processing & Recycling Guide |
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Material |
Processing Method |
Key Parameters |
Recycling Methods |
Innovative Solutions |
| Phenolic (PF) | Compression Molding | Temp: 150-170°C | Pyrolysis: 500°C (produces oil/gas) | Cashew nut oil-modified PF for improved biodegradability |
| Pressure: 10-20MPa | Grinding: As filler in new PF compounds | |||
| Time: 2-5 min/mm thickness | ||||
| Epoxy (EP) | Vacuum Infusion | Temp: 120-180°C | Solvolysis: Glycolysis at 200°C | Bio-based epoxies (e.g, lignin-epoxy) with cleavable ester linkages |
| Resin/Hardener Ratio: 100:30 (DGEBA: Amine) | Microwave-Assisted Degradation: 90% monomer recovery | |||
| Gel Time: 30-90 min | ||||
| Polyester (UP) | Hand Lay-Up | Catalyst: 1-2% MEKP | Mechanical Recycling: Crushed for concrete aggregate | UP resins with hydrolyzable maleate linkages |
| Gel Time: 20-40 min @25°C | Alkaline Hydrolysis: 10% NaOH @90°C | |||
| Post-Cure: 80°C/2h | ||||
| Polyurethane (PU) | Reaction Injection Molding | Isocyanate:Polyol: 1:1 (by volume) | Glycolysis: Dipropylene glycol @200°C (85% recovery) | Self-healing PU networks with dynamic disulfide bonds |
| Mold Temp: 40-80°C | Enzymatic Degradation: Lipase-based (pilot scale) | |||
| Demold Time: 5-10 min | ||||
| Silicone (SI) | Liquid Injection Molding | Cure Temp: 120-200°C | Pyrolysis: 600°C → SiO₂ + energy | Recyclable silicone elastomers with reversible Diels-Alder networks |
| Platinum Catalyst: 5-50 ppm | Devulcanization: Supercritical CO₂ process | |||
| Cycle Time: 30-180 sec | ||||
| Polyimide (PI) | High-Pressure Sintering | Temp: 300-350°C | Supercritical Water Oxidation: 400°C/25MPa → CO₂ + H₂O | Soluble PIs (e.g., fluorinated PI) for chemical recycling |
| Pressure: 10-30MPa | Laser Ablation: Fiber recovery from CFR-PI | |||
| Atmosphere: N₂ purge | ||||
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