Thermosetting molding compounds | Thermosets | Thermosetting plastics
Thermosets have been enjoying a renaissance for several years now. The reasons for this are their excellent processability, high thermal and chemical resistance, low creep tendency, and very good mechanical properties. At the same time, thermosets are inexpensive and can serve as an alternative to expensive high-performance thermoplastics. The curing (chemical cross-linking) of thermosetting molding compounds—also referred to as resin systems—results in highly cross-linked thermosets. They are often used as a matrix for fiber composites, adhesives, casting compounds, and coatings. Duromers/thermosets have become indispensable in many industrial sectors, including the automotive industry, medical technology, and aerospace.
The wide range of applications is achieved through the great variety and modification possibilities of the resins. At SKZ, resin systems are formulated and customized to meet the requirements of a wide range of applications.
Our experience in the field of thermosets:
- Condensation resins (e.g., phenolic resins) and reaction resins (e.g., unsaturated polyester resins, epoxy resins)
- 1K and 2K systems
- Cold curing, hot curing, UV curing
- Incorporation of fillers, fibers, and additives (resin modification)
- Fiber composites
- Synthesis of resin systems
- (Partially) bio-based systems
Services
We offer to conduct market and literature research for the identification of suitable resin systems, taking into account their specific requirements.
The synthesis of thermosetting resins is becoming increasingly important for the development of new and adapted resin systems, e.g., for bio-based alternatives to established systems. In order to be a competent partner for industry in this field, SKZ is further expanding this area of research. Several laboratory reactors are already available.
We deal with the incorporation of fillers and additives by means of various mixing and dispersing aggregates as well as compounding equipment. In addition, we can produce small batches for our customers to order.
The focus is on the characterization of: Reactivity (DSC), processability (rheology), composition (FT-IR and SEM/EDX), dispersion quality (particle measurement technology), mechanical and fracture mechanical properties, thermal properties (DSC, TGA) as well as aging behavior.
In the area of component manufacturing, we can draw on various potting or injection molding processes.
The production of test specimens according to a wide range of standards and special test specimens using press or injection molding processes is part of our numerous customer and R&D activities.
Just as diverse as the application possibilities of thermosets are, there are a wide variety of non-destructive testing options based on ultrasound, X-ray, terahertz and radar technology as well as thermography, among others. These can be used to detect defects such as pores and blowholes in components or during manufacture in the liquid state. Similarly, the curing reaction can be detected inline on the curing component in order to reduce cycle times and increase process reliability.
For the subsequent examination of the properties of new thermoset materials, we produce test specimens for you on our injection molding machines. We produce corresponding (weld line) tensile bars, flow spirals, or universal mold plates according to your specifications and in accordance with current testing standards. We are also happy to carry out the corresponding tests on the test specimens to characterize the material properties. In addition, we also offer component and process simulations.
Many adhesives, such as epoxies, also belong to the class of thermosets. We offer adhesive modifications and tests related to modification (e.g., rheological properties). In addition, we provide support for bonding by DVS-trained personnel. From adhesive selection to feasibility studies, aging (climate change, constant climate, media influence, salt spray, condensation test, cataplasm, etc.) and load-dependent tests, we advise you on the entire process.
Do you want to clean, pre-treat, or analyze the surface of your plastic components? SKZ supports you in selecting mechanical or physical surface pre-treatment processes based on technical and economic criteria.
State-of-the-art equipment for best results and products
In our modern laboratories, we conduct research into the materials of tomorrow. We work closely with industry to make numerous good products even better and, above all, more sustainable. Challenge us. Together, we will find a solution to your problem. Please feel free to contact us.
Technical equipment
- Reactivity
DSC, DEA analysis and rheometer - Processability / flow behavior
Rheometer - Composition
FT-IR and SEM/EDX - Dispersion quality
Particle measurement technology (DLS, SLS), computed tomography
- Mechanical and fracture properties
Universal testing machine (tensile, flexural and KIc tests) - Thermal properties
DSC, TGA - Aging behavior
Various climatic test chambers - Inline quality assurance procedures
e.g. inline thermography: temperature distribution on the component surface directly after demolding
Several glass flasks including heating hoods, stirrer, protective gas supply, and optional distillation apparatus.
Dissolver, rotor-stator disperser, three roll mill, high pressure homogenizer, universal mixer, ultrasonic homogenizer, intensive mixer.
In our technical center, formulations can be prepared and refined, and sample materials for test specimens or prototypes can be produced. Several twin-screw extruders and special extruders (planetary roller extruders, ring extruders, co-kneaders) are available for this purpose. We also have access to a laboratory kneader (“MetaStation”) and a rolling mill.
The following processes are available for processing into hardened molded parts: injection molding (free-flowing molding compounds and BMC), autoclave, vacuum infusion, resin transfer molding (RTM and RTM Light), hand lamination, hot and wet pressing. Squeegee systems, mixers, and various manual application systems for cartridges and different mixing ratios are available for bonding. We offer the following processes for the application of coatings: powder coating system, automatic paint booth, squeegee system, inkjet printer.
