Despite major benefits, foaming processes in the past have been unsuccessful in gaining widespread acceptance for use in injection molding. One of the reasons for this was the poor surface quality of the resultant components. To counteract this problem, LANXESS has developed a new polyamide 6 and polyamide 66 Durethan designed specifically for physical and chemical foaming. “Both materials produce excellent molded part surfaces that in most cases are smooth and flawless with virtually no opalescent streaks or areas that appear porous. They are therefore suitable for applications that also place high demands on the visual quality of the part – such as visible components under the hood,” states Maik Schulte, a development engineer at LANXESS.
The two new polyamides reinforced with 35 percent glass fibers were optimized at each stage in respect of foam formation. As a result, popular blowing agents dissolve very easily in them and produce very homogeneous single-phase solutions when combined with the plastic melt in the plasticizing unit. The rheological properties and nucleation behavior of the two thermoplastics are geared to the production of very fine-cell foams. “This is one of the main reasons for the excellent surface quality and good mechanical properties of the molded parts,” explains Schulte.
The new materials are suitable for a wide range of applications. In automotive engineering, they could be used to make components such as cylinder head covers and fan shrouds. The electrical/electronics industry could use them for plugs/connectors, lamp sockets/holders and housing components for items such as thermostats and DIY tools. There are also many possible applications in the furniture-making industry.
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