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&%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0 &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 *-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ %=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &% ' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 %*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &% )2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 8-8)' :90/300% &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8) &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) )6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 &%=7%*) 1908-8)' :90/300%2 &%=(96 &%=*-00 &%=*-8 &%=8)' &%=*0)< &%=1)6 &%=46)+ &%=8,)61 &%=8)' &0)2(96 Quick Design Reference Guide for RIM Elastomers Rigid Rim Composites Solid Bayfex Foamed Solid Solid PRISM Foamed Solid System Baydur Baydur GS System Baydur STR/F Baydur STR/C Parameters (Unflled) System System (Thin Walled) System System Part Design (t)Wall Thickness (in) 0.2 – 1.0 0.2 – 1.5 0.25 – 4.0 0.125 – 0.5 0.125 – 0.25 0.09 – 0.15 a Use box beam Use box beam Rib Thickness at Root 0.75t t t 0.75t or corrugation or corrugation 0.5 min 0.5 min 0.5 min 0.5 min Draft (degrees) This is +0.25/inch +0.25/inch +0.25/inch +0.25/inch function of Part Draw or greater than greater than greater than greater than 1.0 min 1.0 min Depth one inch of one inch of one inch of one inch of draw draw draw draw Molded Holes/Slots Yes Yes Yes Yes No No Use side pull Use side pull Use side pull Undercuts Slight undercuts or removable or removable or removable No No insert insert insert Snap Fits Possible Possible Possible Possible No No Fillets (Inner Radius)(in) 1/16 1/8 1/8 1/16 1/4 1/4 Finishing No Class A, use Best Surface Class A Class A N/A Class A Class A with veil texture Use bolt and Screw Assembly Thread cuts skin Thread cutting Thread cutting Thread cutting Thread cutting b nut Mold Design and Processing Parameters Metal preffered Metal preffered Metal preffered Metal preffered Material of Construction (depending on (depending on (depending on (depending on Steel Steel prod. volume) prod. volume) prod. volume) prod. volume) Preferred Gating Fan Dam Dam Dam Center/Direct Center/Direct c Shot Time, Max. (sec) 2 (9 ) 9 15 5 5 15 Mold Pressure (psi) 100 100 100 100 200 200 Mold Temperature (°F) 140 – 160 140 – 160 140 – 160 140 – 160 130 – 140 175 – 185 Physical Properties 53.000 – 130,000 – 270,000 – 150,000 – Flexural Modulus (psi) 5,000 – 100,000 Up to 2,000,000 240,000 190,000 310,000 750,000 3 Part Density (lb/in ) 60 – 65 15 – 55 63 – 68 61 – 67 20 – 40 90 – 110 Flexural Strength (psi) N/A 3,000 – 12,000 5,300 – 7,700 9,300 – 10.300 3,500 – 17,000 50,000 Tensile Strength (psi) 1,900 – 4,000 1,000 – 4,800 3,600 – 5,300 5,500 – 6,600 2,500 – 9,000 26,000 Elongation at Break (%) 100 – 360 6 – 10 16 – 29 11 – 12 2.5 2.5 DTUL at 66 psi (°F) N/A 160 – 212 140 – 215 190 – 205 205 400 Hardness (Shore D) 30 – 69 40 – 81 70 – 75 73 – 75 60 – 70 60 – 70 % Reinforcement 0 – 25 N/A N/A N/A 20(mat) 55(mat) a b Root includes both radii. Can also screw through to metal substrate. c Longer shot times are possible with a Bayfex XGT system, which has an extended gel time. TABLE OF CONTENTS Introduction Chapter 4 PART DESIGN FOAMED MATERIALS 5 The RIM Process 31 Foam Rise and Flow 6 Material Descriptions 31 Wall Thickness 32 Rib Design and Confguration Chapter 1 33 Radii/Fillets MATERIAL SELECTION CRITERIA 33 Bosses 9 Aesthetic Considerations 34 Structural Analysis Considerations 10 Functional Considerations 10 Economic Considerations Chapter 5 COMPOSITE MATERIALS Chapter 2 35 Glass Mat GENERAL PART DESIGN 36 Reinforcements 13 Part Stiffness 36 Radii/Fillets 13 Wall Thickness 37 Pads 15 Ribbing Design and Confguration 37 Preforms 17 Ribbing Direction 38 Finishes 18 Draft 19 Bosses Chapter 6 21 Holes, Grooves and Slots POSTMOLDING OPERATIONS 23 Inserts 39 Finishing 23 Metal Stiffening Inserts 39 Pigmentation 24 Wood Stiffening Inserts 40 In-Mold Coatings 24 Threaded Inserts 40 Patching 25 Undercuts 40 Postmold Painting 25 Snap Fits, Wire Guides and Hinges 40 Textures 26 Fillers 41 Decals and Silk-Screening 27 Warpage in Part Design 41 Assembly Operations 27 Creep Considerations 41 Screws 27 Fatigue Considerations 42 Adhesives 28 Back Molding 43 P0stfabrication 43 Nailing/Stapling/Planing Chapter 3 43 Recycling Polyurethanes SOLID MATERIALS 29 Wall Thickness 29 Rib Design and Confguration 30 Radii/Fillets 1 TABLE OF CONTENTS Introduction Chapter 4 PART DESIGN FOAMED MATERIALS 5 The RIM Process 31 Foam Rise and Flow 6 Material Descriptions 31 Wall Thickness 32 Rib Design and Confguration Chapter 1 33 Radii/Fillets MATERIAL SELECTION CRITERIA 33 Bosses 9 Aesthetic Considerations 34 Structural Analysis Considerations 10 Functional Considerations 10 Economic Considerations Chapter 5 COMPOSITE MATERIALS Chapter 2 35 Glass Mat GENERAL PART DESIGN 36 Reinforcements 13 Part Stiffness 36 Radii/Fillets 13 Wall Thickness 37 Pads 15 Ribbing Design and Confguration 37 Preforms 17 Ribbing Direction 38 Finishes 18 Draft 19 Bosses Chapter 6 21 Holes, Grooves and Slots POSTMOLDING OPERATIONS 23 Inserts 39 Finishing 23 Metal Stiffening Inserts 39 Pigmentation 24 Wood Stiffening Inserts 40 In-Mold Coatings 24 Threaded Inserts 40 Patching 25 Undercuts 40 Postmold Painting 25 Snap Fits, Wire Guides and Hinges 40 Textures 26 Fillers 41 Decals and Silk-Screening 27 Warpage in Part Design 41 Assembly Operations 27 Creep Considerations 41 Screws 27 Fatigue Considerations 42 Adhesives 28 Back Molding 43 P0stfabrication 43 Nailing/Stapling/Planing Chapter 3 43 Recycling Polyurethanes SOLID MATERIALS 29 Wall Thickness 29 Rib Design and Confguration 30 Radii/Fillets 3 TABLE OF CONTENTS Introduction MOLD DESIGN Chapter 12 MOLD FINISHING Chapter 7 73 Mold Construction Materials and Fabrication Techniques GENERAL MOLD DESIGN CONSIDERATIONS 73 Material Selection 47 Part Size/Clamping Pressure 74 Steel 48 Mold Costs 74 Aluminum 49 Shrinkage 74 Zinc Alloys (Kirksite) 49 Dimensional Tolerances 74 Nickel Shells 74 Epoxy Molds Chapter 8 75 Mold Construction Techniques GATE DESIGN 75 Milled Block 51 Mixing Head 75 Structural Components 52 Aftermixers 75 Cast 53 Edge Gating 75 Extruded Aluminum Profles 54 Foamed Systems 75 Nickel Plating 54 Dam Gates 76 Surface Treatments for Molds 55 Solid Systems 76 Textures and Finishes 56 Fan Gates 58 Ball Check Chapter 13 58 Center-Gated Direct Fill TECHNICAL SUPPORT 77 Health and Safety Information Chapter 9 77 Design and Engineering Expertise PARTING-LINE CONSIDERATIONS 78 Technical Support 62 Mold Sealing 78 Design Review Assistance 63 Mold Venting 78 Application Development Assistance 64 Mold Filling 78 Product Support Assistance 78 Regulatory Compliance Chapter 10 79 RIM Plastics Recycling OTHER MOLD DESIGN CONSIDERATIONS 79 For More Information 65 Mold Temperature Control 66 Demolding Methods APPENDICES 68 Movable Cores and Inserts 80 List of Figures and Tables 69 Mold Design for Slots 82 Index 69 Shear Edges Chapter 11 SPECIAL MOLDS 71 Multiple-Cavity Molds 72 Self-Contained Molds 4 Introduction TABLE OF CONTENTS PART DESIGN Today, various Reaction Injection The extensive number of RIM Specifc system data and typical Molding (RIM) polyurethane systems polyurethane systems with their property information have not are replacing many traditional various physical and mechanical been included in this manual materials because of their inherent properties can make selecting the right except as examples for general advantages, including: system diffcult. The purpose of this information. All values that appear manual is to help you – the design in this manual are approximate • Large–part molding; . Wall–thickness engineer, product designer and others and are not part of the product variations; who work with RIM polyurethane specifcations. Do not use this data materials – make practical design for product specifcation. For more • Excellent encapsulation capabilities; decisions. specifc information on a particular system, please read the appropriate • Excellent surface reproducibility and This manual is divided into two BaySystems Product Information in–mold paint fnishing; sections: part design and mold Bulletin (PIB). Published data should design. The section on part design be used to screen potential material • Good dimensional stability; begins with a brief discussion of candidates. Your understanding of the RIM polyurethane process and materials and processing and your • Good chemical resistance; design considerations common to all part’s requirements determines the RIM polyurethane systems. Unique suitability of a material for your • Good weatherability. properties and design guidelines product or application. Ultimately, for various polyurethane systems material selection must be based upon Generally, RIM processing uses are discussed next, followed by your prototype testing under actual, less expensive molds, less energy design considerations for assembly end–use conditions. and lower–tonnage presses than and postmolding operations. The thermoplastic processing. These second section of this book contains Bayer MaterialScience offers a full characteristics add up to superior information on mold, gate and runner range of RIM polyurethane systems, design, economic and processing design. including foamed, solid and structural fexibility. composite materials. As a service to Many rules of thumb appear in the our customers, we also have technical text. Naturally, there may be some personnel ready to help you with exceptions to these rules of thumb part design and production. A list of or times when one conficts with these services appears in the back another. If this happens, talk with your of this booklet. Please feel free to mold maker/designer and BaySystems contact us with specifc questions at personnel for appropriate action. While 412 111-2000. this manual provides a good overview of the topics you should address when designing for polyurethane parts, you should also have a good understanding of polyurethane systems before making fnal decisions. For a quick reference, see the part– design matrix on the inside back cover for key information. 5 3FBDUJPO*OKFDUJPO.PMEJOH 3*. 1SPDFTT *MKYVI4 7XMVVIV1SXSV ;EXIV3YX ;EXIV-R 430=30 ,IEX (E]*IIH ,]HVEYPMG )\GLERKIV 8ERO (VMZI ¨&© %MVMR 2YGPIEXSV 7YTTP]0MRI 1IXIVMRK ']PMRHIVSV -73'=%2%8) 1IXIVMRK (E]*IIH 4YQT 8ERO ¨%© 6IXYVR0MRI 8ST1SPH 'SVI ,]HVEYPMG 6IXYVR0MRI (VMZI %GXYEXSV 6IGMVGYPEXMSR %JXIVQM\IV 1M\,IEH 7YTTP]0MRI (EQ+EXI 1IXIVMRK :IRX ']PMRHIVSV 0ERH%VIE 1IXIVMRK7IEPMRK%VIE &SXXSQ1SPH 4YQT'EZMX] 'SSPMRK0MRIW 6 Introduction PART DESIGN THE RIM PROCESS In contrast to thermoplastics where a In fgure P–1, the pressurized day molten plastic is compacted in a mold tanks typically hold from 30 to 250 and then solidifes upon cooling, RIM gallons of isocyanate or polyol. systems are composed of two liquid Recirculation pumps and agitators components that chemically react in maintain a homogeneous blend of the mold. The liquids, isocyanate and the individual components. The heat polyol, are commonly referred to as exchangers maintain components’ the “A side” and “B side” components, temperature. Either high–pressure, respectively, in the United States. metering pumps or hydraulically In Europe, these demarcations are driven chemical cylinders – commonly reversed. A matched set of “A” and referred to as “lances”– meter “B” components is referred to as a isocyanate and polyol into the mixing “RIM system.” head. Flow rates and pressures are precisely controlled to ensure high– Generally, the “B” component contains quality parts. additives such as stabilizers, fow modifers, catalysts, combustion The mix head contains injector nozzles modifers, blowing agents, fller, which impinge the isocyanate and pigments and release agents to polyol at ultra–high velocity to provide modify physical characteristics in excellent mixing. Additional mixing is the fnal part. When the “A” and “B” accomplished using an after–mixer, components combine, the isocyanate typically constructed inside the mold. reacts with the hydroxyl in the polyol to form a thermosetting polyurethane polymer. This reaction is exothermic: when the “A” and “B” components combine, heat is released. To prevent scorching and/or other part defects, cooling lines on the mold help dissipate this heat. 7 Polyurethane Systems Classified by Flexural Modulus Figure P-2 BAYDUR STR/C Solid Composites BAYDUR STR/C Foamed Composites PRISM Rigid Solids BAYDUR Rigid Foams R BAYFLEX R Elastomeric I M Solids 0 300 600 900 1200 1500 1800 3 Flexural Modulus (10 psi) MATERIAL DESCRIPTIONS The degree of rigidity usually defnes systems exhibit good toughness and • Foamed polyurethane systems use a polyurethane system, placing it dimensional stability throughout a a blowing agent to make parts in one of two categories: rigid or wide temperature range and have with a higher–density skin and a elastomeric. A rigid polyurethane excellent corrosion, abrasion, wear and lower density, microcellular core material generally has a higher fexural cut resistance. in a sandwich–like composition. modulus and degree of hardness. Baydur structural foam and other This class of materials normally offers Physical properties for these two rigid systems have hard, solid good thermal resistance, electrical categories are not absolute and skins and are found in business properties, chemical resistance and the fexural moduli ranges of these machines, electronic and medical acoustical insulation. An elastomeric materials overlap (see fgure P–2). housings, automobile spoilers, skis polyurethane system is often found in Within these two classifcations, and other load–bearing applications. applications requiring superior impact the are three types of polyurethane All foamed RIM materials are strength. Elastomeric polyurethane systems (see fgure P–3): microcellular systems, having cells as small as 0.001 inch. 8 Types of Polyurethane Materials Introduction PART DESIGN • Solid polyurethane systems do Figure P-3 Types of Polyurethane Materials not use blowing agents, resulting in a homogeneous, rigid or elastomeric plastic. Bayfex solid elastomeric materials are used in many applications, including the automotive, specialty transportation, construction, agriculture and Solid recreational industries. Common parts include fenders, fascias, trims and vertical panels. Glass or mineral fllers can be added to solid elastomers for improved stiffness. This is commonly referred to as Reinforced RIM or RRIM. Self-Skinning Foam PRISM solid polyurethane systems have many properties similar to those of engineering thermoplastics. They can be used to mold many thicker or thin–walled parts and may be more economical than thermoplastics. Composite • Structural composite polyurethane systems are solid or foamed materials, molded in combination with long–fber reinforcements, such as glass mat, to improve the system’s mechanical characteristics. Sometimes referred to as “SRIM,” for Structural RIM, these systems have extremely high stiffness and high impact strength because of the mat. Typical applications include door panels, shelves, automotive horizontal/ load–bearing panels and recreational equipment parts 9

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