Our Urea Formaldehyde Resin Injection Molding Services
Unlock cost-effective, high-performance solutions with our Urea Formaldehyde (Uf) Resin Injection Molding services. Specializing in thermoset UF process for electrical, automobile, and household industries, we deliver durable, electrically insulating parts—from tight-tolerance components to high-volume runs. Our ISO 9001-certified facility combines automated lines, outillage personnalisé, and expert engineering to meet your unique needs, making us your trusted partner for all UF plastic molding projets.
What Is Urea Formaldehyde Resin Injection Molding?
Urea Formaldehyde (Uf) Resin Injection Molding is a specialized thermoset manufacturing process that uses a resin blend of urea and formaldehyde. Contrairement aux thermoplastiques, UF resin cures permanently under heat and pressure, forming rigid, dimensionally stable parts. Il relève de la catégorie plus large deamino-plastic injection, known for its balance of affordability and performance.
Key defining traits of this process:
- Thermoset Nature: Une fois guéri, UF parts cannot be melted or reshaped, ensuring long-term stability in harsh conditions.
- Applications de base: Dominant in sectors requiring electrical insulation and cost-efficiency, such as electronics and household goods.
- Polyvalence: Blends with fillers (Par exemple, alpha-cellulose, glass fibers) to enhance strength or reduce costs.
Below is a breakdown of core terms to clarifyUF definition molding:
| Terme | Description |
|---|---|
| UF Resin Molding | The overall process of shaping urea formaldehyde resin into parts via injection. |
| Thermoset UF Process | The curing-driven cycle where UF resin hardens permanently under heat/pressure. |
| Urea Resin Injection | The step of forcing molten UF compound into a mold cavity at high pressure. |
| UF Plastic Molding | A casual term for UF resin injection molding, emphasizing the plastic-like final part. |
Our Urea Formaldehyde Injection Molding Capabilities
À la technologie Yigu, we’ve optimized our capabilities to handle the full spectrum ofUF resin molding needs—from small-batch prototypes to massive production runs. Our focus on precision and efficiency ensures consistent quality across every order.
Core Capabilities at a Glance
| Capability | Caractéristiques |
|---|---|
| UF Molding Capacity | Jusqu'à 400,000 unités / mois (high-volume urea molding for large-scale projects) |
| Précision | Tight-tolerance UF parts: As low as ±0.1 mm (ideal for electrical components) |
| Outillage | Multi-cavity UF tools (jusqu'à 24 cavités); in-house toolroom for custom designs |
| Personnalisation | Insert molding UF, over-molding urea, and secondary ops (Par exemple, forage, impression) |
| Prototypage | Rapid prototyping UF resin: 2-4 day turnaround for functional samples |
| Automation | Automated UF lines with real-time quality checks (reduces defects by 25%) |
| Logistics | Global UF supply: Door-to-door delivery to 30+ countries with 98% on-time rate |
Our automated lines are equipped with servo-driven injection units that maintain consistentclamp pressure UF (1500-2800 bar) and mold temperature—critical for replicating precise parts in high volumes. Par exemple, our 24-cavity tool for UF closure caps produces 10,000 units per 8-hour shift, Couper le temps de production par 40% compared to standard 8-cavity tools.
The Urea Formaldehyde Injection Molding Process
LeUF injection cycle is a streamlined sequence of steps that leverages heat and pressure to transform raw UF compound into finished parts. Unlike melamine-formaldehyde processes, UF molding prioritizes speed and cost-efficiency, making it ideal for high-volume applications.
Répartition des processus étape par étape
- Préparation des matériaux: Mélange urea formaldehyde resin (granular or powder) avec des charges (Par exemple, alpha-cellulose filled UF) and pigments (for pigmentable urea resin) to create a homogeneous compound.
- Injection: Feed the compound into a heated barrel, then inject it into a mold at high pressure (1500-2800 bar) et la température (160-190° C).
- Durcissement: Hold the mold closed to allow urea formaldehyde curing—typically 20-60 secondes (cure time UF) at 170-185°C (UF mold temperature).
- Dégazage: Utiliser un degassing urea mold system to remove trapped air, preventing bubbles in parts like electrical housings.
- Démêlé: Eject the cured part. Pour des conceptions complexes (Par exemple, snap-fit connectors), Nous utilisons BMC-UF compression-injection hybrid technology to improve mold filling.
- Post-traitement: Facultatif post-cure urea (120° C pour 30 minutes) to enhance hardness, or secondary ops like drilling or printing.
Key Thermoset Injection Parameters for UF
| Paramètre | Gamme typique | Impact sur la qualité des pièces |
|---|---|---|
| UF Mold Temperature | 160-190° C | Higher temps speed curing; lower temps reduce shrinkage |
| Clamp Pressure UF | 1500-2800 bar | Ensures full mold filling (critical for tight tolerances) |
| Cure Time UF | 20-60 secondes | Shorter times boost output; longer times improve strength |
| Vitesse d'injection | 50-100 mm / s | Faster speeds reduce cycle time; slower speeds prevent flash |
Urea Formaldehyde Resin Materials: Notes & Propriétés
We offer a diverse range ofurea formaldehyde resin notes, each formulated to match specific application needs—from electrical insulation to food-contact safety. All materials meet global standards (Ul, Rohs) and prioritize sustainability (Par exemple, low-formaldehyde variants).
Material Grades & Leurs utilisations
| Grade de matériel | Filler/Additive | Propriétés clés | Target Applications |
|---|---|---|---|
| Electrical-Grade UF | Glass-filled urea (20%) | Excellente isolation électrique, ignifuge | UF electrical housings, wiring devices |
| Low-Formaldehyde UF | Alpha-cellulose filled UF | <0.1% formaldehyde emission, écologique | Household UF tableware, children’s products |
| Food-Contact UF | Aucun (pur) | Conforme à la FDA, non toxique | Food-safe closure caps, utensil handles |
| High-Flow UF | Mineral filler | Easy mold filling for complex shapes | Intricate automotive UF parts, switch internals |
| Pigmentable Urea Resin | Color pigments | Customizable shades (Pantone-matched) | Appliance knobs urea, colored buttons |
Comparaison des performances des matériaux
| Propriété | Electrical-Grade UF | Low-Formaldehyde UF | High-Flow UF |
|---|---|---|---|
| Dureté (Rive D) | 75-85 | 70-80 | 68-78 |
| Résistance à la chaleur | Up to 130°C | Jusqu'à 120 ° C | Up to 115°C |
| Isolation électrique | 10¹⁴ OH · cm | 10¹³ Ω·cm | 10¹² Ω·cm |
| Coût (par kg) | $2.80-$3.20 | $3.00-$3.50 | $2.60-$3.00 |
Surface Treatment for Urea Formaldehyde Parts
To enhance aesthetics and durability, Nous offrons une gamme detraitement de surface options for UF parts. These treatments address common needs like scratch resistance, brillant, et marque.
| Type de traitement | Avantage | Idéal pour |
|---|---|---|
| UF Part Polishing | Crée un lisse, semi-gloss finish | Toilet seat UF, decorative handles |
| High-Gloss Urea Finish | Mirror-like shine (via diamond buff UF) | Appliance knobs urea, high-end closures |
| UV-Coated Urea | Adds anti-scratch UF lacquer (5H hardness) | High-use parts like automotive UF parts |
| Pad-Printing UF | Permanent logos/text (jusqu'à 4 couleurs) | Branded buttons urea resin, largeur de commutation |
| Texture Etching Urea | Non-slip or decorative textures | Industrial UF handles, poignées d'outil |
| Edge-Sealing UF | Prevents moisture absorption | Outdoor UF parts, bathroom accessories |
Par exemple, notresublimation UF treatment for household tableware allows full-color, photo-quality prints that resist fading—even after 500+ dishwasher cycles.
Advantages of Urea Formaldehyde Resin Injection Molding
UF resin molding offers unique benefits that make it a top choice for cost-sensitive, applications hautes performances. Its advantages over other thermosets (Par exemple, melamine, époxy) and thermoplastics (Par exemple, Abs) sont clairs:
- UF Cost Advantage: 15-25% lower material and production costs than melamine-formaldehyde, thanks to faster cycles and cheaper raw materials.
- Electrical Insulation UF: Excels in dielectric strength (15-20 kV/mm), making it the gold standard for UF electrical housings and switches.
- Stabilité dimensionnelle: Low cure shrink (0.5-0.8%) ensures parts retain shape even in temperature fluctuations (from -30°C to 130°C).
- Flame-Retardant UF: Naturally meets UL 94 V0 standards without added flame retardants, critical for electrical applications.
- Fast Molding UF: Temps de cycle plus court (20-60 secondes) than most thermosets—ideal for high-volume runs like closure caps (400k units/month).
- Recyclable Flash UF: Matériel de rebut (éclair) can be ground and reused (jusqu'à 15% of total compound), reducing waste and costs.
Advantage Comparison: UF vs. Melamine-Formaldehyde (MF)
| Avantage | Urea Formaldehyde (Uf) | Melamine-Formaldehyde (MF) |
|---|---|---|
| Coût (par pièce) | Inférieur (15-25% moins) | Plus haut |
| Temps de cycle | Plus rapide (20-60 sec) | Ralentissez (30-120 sec) |
| Isolation électrique | Supérieur | Bien |
| Résistance à la chaleur | Up to 130°C | Up to 200°C |
| Food-Contact Safe | Only FDA-approved grades | La plupart des grades |
Industry Applications of Urea Formaldehyde Parts
UF resin molding sert un large éventail d'industries, driven by its cost-efficiency and electrical insulation properties. Below are the most common use cases:
| Industrie | Applications | Key Material Grade |
|---|---|---|
| Électrique & Électronique | UF electrical housings, interrupteurs, wiring devices | Electrical-Grade UF |
| Appareils | Knobs, panneaux de commande, dryer components | Pigmentable Urea Resin |
| Automobile | Garniture intérieure, boîtiers de connecteur, poignées de porte | High-Flow UF |
| Ménage | Closure caps, tableware (à sa sécurité), toilet seat UF | Low-Formaldehyde/ Food-Contact UF |
| Industriel | Poignées, gardiens de machines, couvercles de soupape | Glass-filled Urea |
Par exemple, dans l'industrie automobile, notrehigh-flow UF is used to produce complex connector housings—its excellent moldability ensures all small pins and slots are filled perfectly, reducing assembly defects by 30%.
Études de cas: Our UF Injection Molding Success Stories
We’ve helped clients across industries overcome production challenges with tailoredUF resin molding solutions. Voici trois cas hors concours:
Cas 1: UL-Listed UF Switchgear Housing
- Client: A leading electrical equipment manufacturer.
- Défi: Produire 100,000 switchgear housings that meet UL 94 V0 flame-retardant standards and ±0.1 mm tolerance for component fit.
- Solution: Used electrical-grade UF with glass filler; optimized clamp pressure UF (2500 bar) et UF mold temperature (180° C) pour précision.
- Résultat: 99.8% taux sans défaut; UL listing obtained in 4 semaines; production cost 20% lower than client’s previous supplier.
Cas 2: Cost-Down UF Lid for Household Jars
- Client: A global food packaging brand.
- Défi: Reduce costs for 500,000 monthly UF closure caps without sacrificing durability.
- Solution: Switched from pure UF to alpha-cellulose filled UF (30% filler); implemented 24-cavity UF tools (up from 12-cavity).
- Résultat: Cost per lid reduced by 18%; hardness maintained (Rive D 75); Taux de livraison à temps 99%.
Cas 3: High-Gloss UF Toilet Seat
Résultat: Product passed 10,000 scratch tests; UV resistance rating of 4+ (no fading after 2 années); Satisfaction du client 95%.
Client: A sanitary products company.
Défi: Create a high-gloss toilet seat UF with scratch resistance and UV stability (for bathroom sunlight exposure).
Solution: Used pigmentable urea resin with diamond buff UF polishing and UV-coated urea (5H hardness).
Why Choose Yigu Technology for Urea Formaldehyde Injection Molding?
We stand out as a trustedUF resin molding partner for 5 core reasons—backed by data and expertise:
Fiabilité: 24/7 UF tech support (average response time <2 heures); on-time UF delivery rate 98% (even for urgent orders).
UF Resin Expertise: 12+ years specializing in thermoset UF processes; our engineers have solved 200+ unique UF molding challenges (Par exemple, tight-tolerance parts, couleurs personnalisées).
Assurance qualité: OIN 9001 urea plant with in-house testing labs (tests for hardness, isolation, résistance aux flammes); 99.5% average defect-free rate.
Rentabilité: Competitive UF pricing (10-15% below market average) thanks to automated lines and recyclable flash usage; Pas de frais cachés.
One-Stop Service: From DFM (Conception pour la fabrication) for UF molding to global logistics—we handle every step, saving you time and hassle.