POLYMER AND CERAMIC BDB 4063

CHAPTER 1 INTRODUCTION

Component: Household Application ( Blender)

Blender is make from polymer plastics. In plastics have two type Thermosets and Thermoplastic. In this case, thermosest type me choice is Melamine formaldehyde (MF) thermosets.

1.1. What is Melamine formaldehyde (MF) thermosets Melamine formaldehyde (MF) also react further at room temperature .This showns itself in a decrease of flowability ,it can be so formulated that they are suitable for tropical use. Therequisite for manufacture of molded articles which do not subquently shrink is that molding compounds must be dry. MF molding compounds absorb less moisture when immersed in cold
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POLYMER AND CERAMIC BDB 4063

water than UF moldings. However the nature of the filler has a large effect. Wood flour,cellulose and textile reinforcements are poorer than asbestos .mica and textile glass material. melamine formaldehyde (also shortened to melamine) is a hard,thermosetting plastic material made from melamine and formaldehyde by polymerization. In its butylated form, it is dissolved in n-butanol and xylene. It is then used to cross-link with alkyd,epoxy, acrylic, and polyester resins, used in surface coatings. There are many types, varying from very slow to very fast curing. It was initially discovered by William F. Talbot. These thermosetting plastics, also called amino resins because they are produced by the reaction of amines, or compounds bearing the amino group (-NH2), with formaldehyde, are clear and colourless, a distinct advantage over the phenolics. They also have better hardness and tensile strength than phenolics, but their impact strength and moisture resistance are lower. Ureas have lower hardness, heat resistance and moisture resistance than melamines. Amino resins are used in the fabrication of industrial and decorative laminates, adhesives, protective coatings, paper manufacture, and moulding compounds. Melamine is one of the thermosetting plastics that can be made in unlimited colours. Articles fabricated from melamines are rigid and have one of the hardest surface finishes of any plastic material. Because of this they are widely used for the production of decorative laminates, which are usually assembled from a core of phenolic resin-impregnated paper and a melamine impregnated overlay sheet.

Figure:Idealized structure of melamine formaldehyde

POLYMER AND CERAMIC BDB 4063

1.2. Melamine formaldehyde (MF) thermosets characteristics:

-high surface hardness and scratch resistenace -high surface gloss. -high resistance to creep -resistant to heat(up to 250 c/482 F for special grades), -resistant to moisture -not suitable for continuous contact with boiling water, -high shrinkage as for Urea Formaldehyde(UF) molding compounds,

1.3. Melamine formaldehyde (MF) thermosets application:

-table tops, dinnerware, protective coatings, adhesives, lighting fixtures, heavy duty electrical equipment, decorative laminates, housings,basins,grips ,screw caps, installation material,switches and spark arresting chambers.

Construction material
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POLYMER AND CERAMIC BDB 4063

Melamine resin is the main constituent of high-pressure laminates, such as Formica and Arborite, and of laminate flooring. Melamine-resin tile wall panels can also be used as whiteboards. Melamine & LEED: Phenol formaldehyde (PF) is used typically used as the binder / resin in hard-surface countertop materials, such as those used in lab desks. Melamine formaldehyde (MF) is a related compound used in plastic laminate and overlay materials. Formaldehyde is more tightly bound in PF and MF than it is in Urea Formaldehyde, reducing emissions. LEED v2.2's EQ Credit 4.4 precludes the use of Urea-Formaldehyde, but allows the use of Melamine Formaldehyde.

CHAPTER 2
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POLYMER AND CERAMIC BDB 4063

MELAMINE FORMALDEHYDE MANUFACTURE AND PROCESSING TECHNIQUES

2.1.Chemical Compound

Melamine formaldehyde(MF) are resistent to water(hot and cold), weak alkaline solution, alcohols,wsters,ether,benzene,petrol,mineral oil,fats; theyare resistant to weak acids under certain conditions but not resistent to strong acids and strong alkalis. Melamine can be manufactured from dicyandiamide, hydrogen cyanide, or urea. Modern commercial production of melamine typically employs urea as a starting material. Urea is broken down to cyanuric acid, which then can be reacted to form melamine. Its most important reaction is that with formaldehyde, forming melamine-formaldehyde resins of high molecular weight. These compounds form under the influence of heat and then become fixed into an insoluble and infusible mold; this process is known as thermosetting. Melamine-based thermoset materials contain cross-linked polymers, which make the fixed molds strong and durable. The mechanism of resinification and cross-linking is similar to that observed for ureaformaldehyde and involves methylol-amine and methylol-methylol condensations.

Cellulose Filled MF is a subcategory of Melamine formaldehyde. The additative is added during the manufacturing process. Its elastic modulus ranges from 1100 to 1400 MPa. Its
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POLYMER AND CERAMIC BDB 4063

tensile strength ranges from 5000 to 13000 MPa at break. Its flexural strength ranges from 9000 to 16000 MPa. Its compressive strength ranges from 33000 to 45000 MPa. Its Izod Impact strength ranges from 0.2 to 0.4 J/cm. Its elongation at break ranges from 0.6 to 1 %. Its hardness ranges from 115 to 125 Rockwell M. Its specific gravity ranges from 1.47 to 1.52. Its coefficient of thermal expansion ranges from 40 to 45 x 10-6/C. Its molding pressure ranges from 8 to 20 Mpa

Figure: urea-formaldehyde

Figure: Reactions in the synthesis of formica

POLYMER AND CERAMIC BDB 4063

Figure :Structure of monomer of melamine-formaldehyde resin

2.2. Properties of Melamine Formaldehyde (MF) Thermoset Melamine Formaldehyde (MF), cellulose filled Property Density Modulus of elasticity Tensile strength Elongation Flexural yield strength Compressive strength Thermal expansion (20 C) Maximum work temperature Value in metric unit 1.55 *10 kg/m 12 65 0.6 140 240 29*10 150
-6

Value in US unit 96.8 lb/ft 1800 ksi 9500 psi 0.6 % 20000 psi 35000 psi 16*10-6 in/(in* F) 300 F

GPa MPa % MPa MPa C C

Table of Properties of Melamine Formaldehyde (MF)

Thermosetting Materials

Tensile Elongation, Tensile Compressive Flexural Hardness** Strength, % (ASTM Modulus, Strength, psi, Yield 5 psi (ASTM D-638) 10 psi (ASTM D-695) Strength, D-638) (ASTM Dpsi, (ASTM 638) D-790)

Melamineformaldehyde (moulding compounds)

5,00013,000

0.3-0.9

11.0-24.0 20,000-45,000
7

9,00023,000

M110M125

POLYMER AND CERAMIC BDB 4063

Table of Typical Range of Mechanical Properties of Thermosetting Plastics (Filled or Reinforced)

Thermosetting Material

Melamineformaldehyde

Burning Rate (Flammability), in./min., (ASTM D-635) Very slow burning, self-ext or nonburning

Coeff of Resistance to Water Chemical Therm Heat Absorption, Resistance*(room Exp. (continuous), % (ASTM Dtemperature) 1005/F F 570) 0.8-2.5 210-400 0.08-0.80 May resist or undergo slight attack by weak acids and alkalis but decomposes in strong acids and alkalis. Reinforced)

Table of General Properties of Commercial Thermosetting Plastics (Filled or

Thermoset materials do not dissolve, and only swell if they interact with solvents. Many thermoset materials do not swell appreciably in contact with any solvent, but some of the compounding ingredients may be leached out.

2.3 Advantage & Disadvantage of Melamine Formaldehyde (MF) The are have several advantange and disadvantage : Advantages: -good dielectric properties -better resistance to creep -grades filled with MF molding compunds.
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POLYMER AND CERAMIC BDB 4063

-less shrinkage -less tendency to stress crack formation when exposed to moisture and heat, -lower cost. Disadvantages: -Inferior to Phenolic in dimensional stability in hot dry conditions. -More expensive than Urea or Phenolic. -Limited resistance to concentrated acids and alkalies

2.4 PROCESSING TECHNIQUES Properties of MELAMINE & UREA (Amino Moulding Powders) These thermoset materials give a unique combination of moulded properties which are unmatched by any other plastic raw materials in the same price range, making them ideal for a wide range of applications, particularly in the domestic field. Of especial importance is their ability to not soften or melt on heating as thermoplastics do, this being a result of irreversible cross linking of the polymer that takes place during the moulding process (compression or injection) under conditions of heat and pressure.
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POLYMER AND CERAMIC BDB 4063

UREA Urea formaldehyde (UF) materials combine a virtually unlimited range of colours and excellent colour retention with good electrical properties, solvent resistance, high flame retardance, high rigidity, surface hardness and scratch resistance and permanent anti-static properties. Uses: Electrical components, closures, toilet seats MELAMINE The melamine formaldehyde (MF) materials give mouldings with a superior surface performance to UF materials. Their excellent stain resistance and low formaldehyde extraction properties make them suitable for food contact applications such as table and kitchenware whilst their greater heat resistance makes them ideal for such items as ashtrays. Uses: Tableware, Kitchenware, Knobs and components for white goods, electrical accessories PHENOLIC (Bakelite) Phenolic (Bakelite) moulding compounds are based on a phenol-formaldehyde resin processed with inert fillers, cross-linking agents, accelerators, and pigments or dyestuffs. They can be readily tailored to suit specific property or mouldability requirements. They are low cost thermosetting materials capable of being moulded under heat and pressure to give flow then permanent setting to a desired form. Phenolic mouldings have good electrical properties, heat resistance, moisture resistance, dimensional stability, high surface hardness and mechanical strength. Uses: Electrical components, knobs and components for white goods, meter parts, automotive components, cookware handles and fittings. Dough (Bulk) Molding Compound Dough (Bulk) Molding Compound (DMC sometimes referred to as Bulk Moulding Compound usually abbreviated to BMC) is a thermoset plastic resin blend of various inert fillers, fiber reinforcement, catalysts, stabilizers, and pigments that form a viscous, putty like, compound for compression or injection molding. DMC is highly filled and reinforced with short fibers. Glass
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POLYMER AND CERAMIC BDB 4063

reinforcement represents between 10% and 30%, with glass length typically between 1mm and 12.5mm. Depending on the end-use application, compounds are formulated to achieve close dimensional control, flame and track resistance, high dielectric strength, corrosion and stain resistance, superior mechanical properties, low shrink, and color stability. Its excellent flow characteristics and electrical and flame resistant properties make DMC well suited to a wide variety of applications requiring precision in detail and dimensions. The material is available in a wide variety of colors, and can tolerate powder-coat or water-based paint. Uses: Electrical components, white goods components, hifi components, cookware, telecommunication components, lighting components.

Sheet Molding Compound Sheet Molding Compound (SMC) is used in compression molding, often of larger parts, where higher mechanical strengths need to be achieved. Glass reinforcement is between 10% and 60%, and glass length is slightly longer than DMC, between 12.5mm and 25mm. As with DMC, thermoset SMC is a mixture of polymer resin, inert fillers, fiber reinforcement, catalysts, pigments and stabilizers, release agents, and thickeners. Manufacture of SMC is a continuous in-line process. The material is sheathed both top and bottom with a polyethylene or nylon plastic film to prevent auto-adhesion. The paste is spread uniformly onto the bottom film. Chopped glass fibers are randomly deposited onto the paste. The top film is introduced and the sandwich is rolled into a pre-determined thickness. The sheet is allowed to mature for 48 hours. SMC can be molded into complex shapes. High mechanical properties and excellent surface appearance make SMC ideal for automotive Class A body panels, high-strength electrical parts, business equipment cabinets, personal watercraft, and various structural components. Uses: Automotive components, mass transit components, building and construction components. Lighting components. MELAMINE FORMALDEHYDE AMINO RESINS
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POLYMER AND CERAMIC BDB 4063

ATEC has conducted extensive R & D work to develop and perfect numerous Melamine Formaldehyde Amino Resin formulations and owns the related technologies, (process KnowHow /design /engineering) to manufacture various liquid and powder resin grades. ATECs patented melamine formaldehyde resin grades are: ATMFORM 102 L/102 P These are liquid and powder grades of unmodified Melamine Formaldehyde powder Resins suitable for impregnation of base /decorative papers and overlay in the manufacture of high pressure decorative laminates, low pressure melamine surfaced wood boards /panels etc. Typical Powder Resin Specifications are : Appearance Bulk Density g /cc (minimum) Volatiles pH (50 % soln.), 25C Viscosity Dilution in water Gel time 50 % soln., @ 150C Free formaldehyde % ATMFORM 105 L 105 P These are liquid and powder grades of precatalysed Melamine Formaldehyde Resin for the said end use application. Typical specifications of powder (ATMFORM 105 P) Resin are : : : : : : : : : White free flowing powder 0.55 3 9.3 9.7 30 3 Up to 25 % solids 260 20 seconds 0.6 0.05

Appearance Bulk density g /cc (Minimum) Volatiles 105 C /1 hr, % (Max.) pH (50 % soln.), 25C Viscosity OF 50 % soln. (25C), Cps Dilution in water Water tolerance (50 % Soln.)% Gel time 50 % Soln.,150c spatula method (sec.) Free formaldehyde %

: White free flowing powder : 0.55 :3 : 8.8 + 0.2 : 30 3 : up to 25 % solids : 120 + 20 : 80 + 10 : 0.6 0.05

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POLYMER AND CERAMIC BDB 4063

ATMFORM 108 L /108 P ATMFORM 108 P is a powder Melamine Formaldehyde Resin used for glazing of Amino moulded articles viz. Melamine based crockery. The same resin can be used for the impregnation of overlay papers also. Basically ATMFORM 108 P is used in powder form for glazing application, while it needs to be reconstituted into solution form by dissolving in water for impregnation of papers. Typical specifications of powder (ATMFORM 108 P) are : Properties Appearance Bulk density (g/cm) Free formaldehyde (%) Volatiles (105C/1 hr ) % Gel time at 150 C (seconds)50 % solutions properties Appearance Water tolerance pH at 25C Viscosity at 25C Specification White free flowing powder Min 0.400 0.600 0.10 >4 25-45.

: : : : :

: Water white to slightly hazy liquid free from suspended impurities and dissolved particles : 50-120 : 7.4-8.4 : 25-35 Cps

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POLYMER AND CERAMIC BDB 4063

CHAPTER 3 DISCUSSION AND CONCLUSION

3.0 Discussion and Conclusion

For discussion in chemical Properties Melamine formaldehyde molded material are resistent to water (hot and cold), weak alkaline solutionsi and in MF molding compound are available as powder ,fibers, chips or granules. In this thermoset it have advantage and disadvatages and for that wa must develop for green technology for earth save.

Melamine formaldehyde is a thermosetting plastic (or thermoset) that strengthens as it is heated during its preparation. Once set, it cannot be remolded or set to form a different shape. Melamine formaldehyde plastics retain their strength and shape, unlike other types of thermoplastics that soften with heat and harden when cooled (such as acetate, acrylic and nylon)

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REFERENCES

1.

.Plastics for Engineers Material,Properties, Applications, Hons Domininghaus, Hanser Publishers , New York, 1993.

2.

.Guide to Plastics, by the Editors of Modern Plastics Encyclopedia, McGraw Hill, Inc., New York, 1970.

3.

.Fourth Edition Plastics Technology Handbook, Manas Chanda, Salil K. Roy, CRC Press, U.S, 2007.

4.

Third Edition PLASTICS material and Processing , Strong ,A.Brent , PearsonEducation Ltd,US,2006

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