Our Phenolic Resin Bakelite injection molding Services

Elevate your industrial components with Yigu Technology’s Phenolic Resin Bakelite Injection Molding services—the trusted solution for high-performance, heat-resistant thermoset parts. From UL-rated switchgear to food-safe cookware handles, we combine advanced multi-cavity tooling, clean-room production, and specialized phenolic formulations to deliver parts that excel in extreme conditions. Backed by ISO 9001/IATF 16949 certifications and 24/7 soutien, we turn your Bakelite molding challenges into reliable, solutions rentables.

phenolic resin bakelite injection molding
phenolic resin bakelite injection molding

What Is Phenolic Resin Bakelite Injection Molding?

Phenolic Resin Bakelite Injection Molding is a specialized manufacturing process that shapes phenol-formaldehyde (PF) résine—commonly known as Bakelite—into durable parts via high-pressure injection into precision molds. Unlike thermoplastics that soften when heated, Bakelite is a thermoset phenolic; once cured, it retains its shape and properties even at extreme temperatures, making it ideal for applications needing long-term stability.​

À la base, Bakelite plastic molding leverages the material’s unique cross-linked molecular structure. During molding, the phenolic resin cures (hardens permanently) under heat and pressure, creating parts with unbeatable heat resistance and electrical insulation. C'est pourquoi PF (phenol-formaldehyde) moulage is the go-to choice for industrial, automobile, and electrical components that face harsh conditions.​

Key Traits of Phenolic Resin Molding​

TraitDescriptionRelevance to Molding​
Thermoset BehaviorCures irreversibly; no re-melting after forming​Ensures parts retain shape in high-heat environments​
Cross-Linked StructureMolecular bonds form a rigid, 3D network during curing​Delivers exceptional dimensional stability and creep resistance​
High Heat ToleranceTypical continuous use temp: 150–200 ° C (up to 300°C short-term)​Ideal for cookware, automobile, and industrial heat-exposed parts​
Isolation électriqueLow dielectric constant (3.5–5,0) and high volume resistivity​Perfect for switchgear, connecteurs, and electrical housings​

Our Phenolic Resin Bakelite Injection Molding Capabilities: Power Meets Precision

Technologie Yigu Bakelite injection molding capacity is built to handle diverse industrial needs—from small-batch prototypes to high-volume production—while maintaining strict quality standards. Our facility specializes in thermoset challenges, with a focus on tight tolerances and versatile molding techniques.​

Répartition des capacités de base

CapacitéSpécificationApplications idéales
Contrôle de la tolérance±0.02 mm for standard parts; ±0.01 mm for precision components​Electrical connector housings, RF terminals​
Multi-Cavity Phenolic ToolingUp to 64-cavity molds (for small parts like knobs)​High-volume cookware handles, appliance controls​
Production à volume élevé5–8 million parts/year (via automated lines)​Automotive commutators, brake-pad backings​
Clean-Room Phenolic ServiceClasse 8 (100,000) certified rooms​Food-contact cookware, composants de dispositifs médicaux
Insert & Over-Molding BakeliteCompatible with metals (laiton, acier) and plastics​Motor end-caps, clutch cylinders with metal inserts​
Post-Mold Machining & TapotementCNC drilling, filetage (up to M12 size)​Industrial bobbins, switchgear mounting brackets​

The Phenolic Resin Bakelite Injection Molding Process: Step-by-Step Precision

Thermoset phenolic molding requires careful control of heat, pression, and curing time—mistakes here can ruin parts. Our optimized process ensures consistent, high-quality Bakelite components every time.​

Étape 1: Resin Preparation​

We start with dry résine phénolique boulettes (teneur en humidité <0.1% pour éviter les bulles). Pour des pièces spécialisées, we blend additives: glass fibers (pour la force), pigments (pour la couleur), ou retardateurs de flamme. Glass-filled Bakelite compounds are mixed in a twin-screw extruder to ensure even distribution.​

Étape 2: Mold Setup & Temperature Control​

The mold is preheated to the Bakelite cure temperature window (160–190°C) using cartridge heaters. Nous utilisons cold-runner & hot-pot mold design—the hot pot keeps resin molten, while cold runners prevent premature curing, reducing waste by 25% contre. traditional designs.​

Étape 3: Injection & Durcissement

Resin is injected into the mold at 800–1,500 bar pressure. The key is thermoset cycle time optimization: we hold pressure for 30–90 seconds (en fonction de l'épaisseur de partie) to let the resin cure fully. Thicker parts (Par exemple, brake-pad backings) need longer hold times (60–90s) to avoid internal cracks.​

Étape 4: Démêlé & Deflashing​

Après guérison, parts are demolded gently (Bakelite is brittle when cool). We use automated degating & flash control—trim robots remove runners, et phenolic deflashing media (granulés en plastique) bords lisses. Pour les pièces de haute précision, we add Bakelite vibratory tumbling (10–15 minutes) to eliminate micro-flash.​

Étape 5: Post-Mold Finishing & Inspection

Parts go through post-mold machining & tapotement si nécessaire (Par exemple, threading for mounting holes). We then inspect 100% des pièces: chèques dimensionnels (via la MMT), heat-resistance tests (200° C pour 24 heures), and electrical insulation checks (per UL standards).

Phenolic Resin Bakelite Materials: Formulations for Every Need

The right phenolic formulation makes or breaks a part. Nous offrons une gamme de phenolic resin grades tailored to industry-specific demands—from heat-resistant automotive parts to food-safe kitchen tools.​

Popular Phenolic Formulations We Offer​

Formulation Type​Propriétés clésTarget Applications​
General-Purpose Phenolic ResinBonne force, rentable, temp resistance up to 150°C​Industrial bobbins, Boutons d'appareil
Glass-Filled Bakelite Compounds30–50% higher tensile strength (50–70 MPA), résistance à l'impactBrake-pad backings, motor end-caps​
Electrical-Grade Phenolic MoldingUl 94 V0 rated, low dielectric loss, high insulation resistance​Largeur de commutation, electrical connector housings​
Heat-Resistant Phenolic ResinContinuous use temp up to 200°C, short-term up to 300°C​Toaster bases, steam-iron thermostats​
Low-Emission PF Formulations<0.1% formaldehyde emission, RoHS compliant​Indoor electrical components, consumer appliances​
Food-Contact Approved PhenolicFDA 21 CFR 177.2420 conforme, non toxiquePoignées d'ustensiles de cuisine, food processor parts​

Phenolic Resin Bakelite Surface Treatment: Enhancing Function & Esthétique

Bakelite’s natural surface is smooth but can benefit from treatment to boost durability, imprimabilité, or bonding. Our surface services ensure parts meet both functional and visual requirements.​

Common Surface Treatments for Bakelite​

Méthode de traitementButAvantages
Phenolic Shot-Blast FinishCrée un mat, surface uniforme; removes residual flash​Améliore l'adhérence (for knobs); enhances paint adhesion​
Surface Sealant for PhenolicSeals porous areas in the resin​Prevents moisture absorption; increases chemical resistance​
Bakelite Pad-Printing PrimerPrepares surface for ink adhesion​Enables clear, long-lasting logos/text (for appliances)​
Plasma Treat for BondingIncreases surface energy​Improves bonding with adhesives (for over-molded parts)​
Phenole Lacquer CoatingAdds a glossy, protective layer​Améliore l'esthétique; résiste aux rayures (for visible parts)​

Advantages of Phenolic Resin Bakelite: Why It Outperforms Other Materials

Bakelite stands out among thermosets and thermoplastics for its unbeatable combination of durability, rentabilité, et les performances. Here’s why it’s the top choice for tough applications:​

  • Phenolic Heat Resistance Benefit: Handles 150–200°C continuous use (contre. 80–120°C for ABS plastic)—perfect for toasters, composants du moteur, and industrial ovens.​
  • Bakelite Dimensional Stability: Shrinks only 0.5–1.5% during curing (contre. 2–5% for nylon), ensuring parts fit perfectly even after years of use.​
  • Phenolic Electrical Insulation: Acts as a reliable insulator in high-voltage environments (up to 10kV)—critical for switchgear and power connectors.​
  • Low-Smoke Bakelite Advantage: Emits minimal smoke when heated (per UL 94 normes), making it safe for enclosed spaces like aircraft cabins.​
  • Cost-Effective Thermoset Value: 20–30% cheaper than PEEK (un thermoplastique haute performance) while offering similar heat resistance.​
  • Phenolic Creep Resistance: Maintains shape under constant stress (Par exemple, brake-pad backings under pressure), outlasting rubber or plastic alternatives.​

Bakelite Chemical Inertness: Résiste aux huiles, solvants, and most household chemicals—ideal for automotive and industrial settings.

Phenolic Resin Bakelite Applications: Across Key Industries

Bakelite’s versatility makes it indispensable in industries where reliability under stress is non-negotiable. Our clients trust our molding expertise to create parts that solve their toughest challenges.​

Applications industrie par industrie & Solutions​

IndustrieApplications clésOur Molding Solution​
ÉlectriquePhenolic molded switchgear, electrical connector housings, RF terminals​Electrical-grade resin, Ul 94 V0 compliance, tolérances étroites (± 0,01 mm)​
AppareilsBakelite cookware handles, toaster bases, steam-iron thermostats​Food-contact approved resin, heat-resistant formulations (200° C)​
AutomobilePhenolic automotive commutators, brake-pad backings, clutch cylinders​Glass-filled Bakelite, IATF 16949 certified production, insert molding​
IndustrielPhenolic industrial bobbins, composants de la pompe, gardiens de machinesHigh-strength formulations, post-mold machining, chemical-resistant sealants​
AérospatialPhenolic aerospace terminal blocks, boîtiers avioniquesLow-emission PF, flame-retardant grades, full traceability​

Étude de cas: UL-Rated Circuit-Breaker Case for an Electrical Manufacturer

A leading electrical supplier needed a UL-rated circuit-breaker case that could withstand high voltage (600V), resist heat (180° C), and meet strict dimensional standards. Their previous plastic case (Abs) failed UL testing due to poor heat resistance.​

Notre solution:​

  1. Sélection des matériaux: Choisi electrical-grade phenolic molding resin with UL 94 V0 flame rating and high dielectric strength (20 kV/mm).​
  1. Conception de moisissure: Used a 16-cavity cold-runner mold to reduce waste and ensure uniform curing. Added precision pins to meet the ±0.01 mm tolerance for mounting holes.​
  1. Optimisation du processus: Set mold temperature to 180°C, injection pressure to 1,200 bar, and cure time to 45 secondes. Ajouté post-mold tapping for terminal connections.​

Résultats:​

  • The case passed UL 489 essai (600V, 10kA short-circuit rating) with no failures.​
  • Dimensional accuracy stayed within ±0.008 mm (exceeding the client’s ±0.01 mm requirement).​
  • Production cost was 25% lower than using PEEK (the client’s initial alternative).​

The client scaled up to 500,000 units/year with our high-volume lines.

Why Choose Yigu Technology for Phenolic Resin Bakelite Injection Molding?

Quand il s'agit de phenolic resin Bakelite injection molding, Yigu Technology stands out for our deep thermoset expertise, Contrôle de qualité strict, et une approche centrée sur le client. Here’s why clients worldwide trust us:​

  • Certified Quality: Our plant holds ISO 9001 (qualité générale) et IATF 16949 (automobile) certifications—ensuring compliance with global industry standards.​
  • End-to-End Expertise: Depuis in-house Bakelite tool design (using SolidWorks and MoldFlow) to global logistics, we handle every step of your project.​
  • Prototypage rapide: Get functional Bakelite prototypes in 7–10 days (contre. 2–3 weeks from competitors) to speed up your product development.​
  • 24/7 Phenolic Production Support: Our team is available around the clock to resolve issues—critical for high-volume automotive and electrical clients.​
  • Competitive Bakelite Part Pricing: We leverage bulk resin purchasing and efficient cold-runner molds to offer prices 15–20% below market averages.​
  • Full Traceability: Provide PPAP documentation (pour l'automobile) and UL traceability (for electrical parts) to simplify your compliance process.​

Global Reach: Notre global phenolic logistics network delivers JIT (just-in-time) à 40+ countries—reducing your inventory costs.

FAQ

Faites défiler en haut