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 поддерживать, we turn your Bakelite molding challenges into reliable, рентабельные решения.
What Is Phenolic Resin Bakelite Injection Molding?
Phenolic Resin Bakelite Injection Molding is a specialized manufacturing process that shapes phenol-formaldehyde (PF) смола—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.
По своей сути, 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. Вот почему PF (phenol-formaldehyde) формование is the go-to choice for industrial, Автомобиль, and electrical components that face harsh conditions.
Key Traits of Phenolic Resin Molding
| Черта | Описание | Relevance to Molding |
| Thermoset Behavior | Cures irreversibly; no re-melting after forming | Ensures parts retain shape in high-heat environments |
| Cross-Linked Structure | Molecular bonds form a rigid, 3D network during curing | Delivers exceptional dimensional stability and creep resistance |
| High Heat Tolerance | Typical continuous use temp: 150–200 ° C. (up to 300°C short-term) | Ideal for cookware, Автомобиль, and industrial heat-exposed parts |
| Электрическая изоляция | Low dielectric constant (3.5–5.0) and high volume resistivity | Perfect for switchgear, разъемы, and electrical housings |
Our Phenolic Resin Bakelite Injection Molding Capabilities: Power Meets Precision
Yigu Technology's 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.
Основные возможности поломки
| Способность | Спецификация | Идеальные приложения |
| Контроль толерантности | ±0.02 mm for standard parts; ±0.01 mm for precision components | Electrical connector housings, RF terminals |
| Multi-Cavity Phenolic Tooling | Up to 64-cavity molds (for small parts like knobs) | High-volume cookware handles, appliance controls |
| Масштабная продукция | 5–8 million parts/year (via automated lines) | Automotive commutators, brake-pad backings |
| Clean-Room Phenolic Service | Сорт 8 (100,000) certified rooms | Food-contact cookware, Компоненты медицинского устройства |
| Insert & Over-Molding Bakelite | Compatible with metals (латунь, сталь) and plastics | Motor end-caps, clutch cylinders with metal inserts |
| Post-Mold Machining & Tapping | CNC drilling, резьба (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, давление, and curing time—mistakes here can ruin parts. Our optimized process ensures consistent, high-quality Bakelite components every time.
Шаг 1: Resin Preparation
We start with dry фенольная смола гранулы (содержание влаги <0.1% to avoid bubbles). Для специализированных частей, we blend additives: glass fibers (для силы), pigments (для цвета), or flame retardants. Glass-filled Bakelite compounds are mixed in a twin-screw extruder to ensure even distribution.
Шаг 2: Mold Setup & Temperature Control
The mold is preheated to the Bakelite cure temperature window (160–190°C) using cartridge heaters. Мы используем cold-runner & hot-pot mold design—the hot pot keeps resin molten, while cold runners prevent premature curing, reducing waste by 25% против. traditional designs.
Шаг 3: Инъекция & Выклятый
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 (в зависимости от толщины части) to let the resin cure fully. Thicker parts (НАПРИМЕР., brake-pad backings) need longer hold times (60–90s) to avoid internal cracks.
Шаг 4: Демольд & Deflashing
После лечения, parts are demolded gently (Bakelite is brittle when cool). We use automated degating & flash control—trim robots remove runners, и phenolic deflashing media (Пластиковые гранулы) гладкие края. Для высоких частей, we add Bakelite vibratory tumbling (10–15 минут) to eliminate micro-flash.
Шаг 5: Post-Mold Finishing & Осмотр
Parts go through post-mold machining & постукивание При необходимости (НАПРИМЕР., threading for mounting holes). We then inspect 100% части: Проверки размеров (via CMM), heat-resistance tests (200° C для 24 часы), and electrical insulation checks (per UL standards).
Phenolic Resin Bakelite Materials: Formulations for Every Need
The right phenolic formulation makes or breaks a part. Мы предлагаем ряд 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 | Ключевые свойства | Target Applications |
| General-Purpose Phenolic Resin | Хорошая сила, рентабельный, temp resistance up to 150°C | Industrial bobbins, ручки прибора |
| Glass-Filled Bakelite Compounds | 30–50% higher tensile strength (50–70 МПа), воздействие сопротивления | Brake-pad backings, motor end-caps |
| Electrical-Grade Phenolic Molding | UL 94 V0 rated, low dielectric loss, high insulation resistance | Распределительный устройства, electrical connector housings |
| Heat-Resistant Phenolic Resin | Continuous 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 Phenolic | FDA 21 CFR 177.2420 соответствие, нетоксичный | Cookware handles, food processor parts |
Phenolic Resin Bakelite Surface Treatment: Enhancing Function & Эстетика
Bakelite’s natural surface is smooth but can benefit from treatment to boost durability, printability, or bonding. Our surface services ensure parts meet both functional and visual requirements.
Common Surface Treatments for Bakelite
| Метод лечения | Цель | Преимущества |
| Phenolic Shot-Blast Finish | Создает матовый, равномерная поверхность; removes residual flash | Улучшает сцепление (for knobs); enhances paint adhesion |
| Surface Sealant for Phenolic | Seals porous areas in the resin | Prevents moisture absorption; increases chemical resistance |
| Bakelite Pad-Printing Primer | Prepares surface for ink adhesion | Enables clear, long-lasting logos/text (for appliances) |
| Plasma Treat for Bonding | Increases surface energy | Improves bonding with adhesives (for over-molded parts) |
| Phenole Lacquer Coating | Adds a glossy, protective layer | Улучшает эстетику; сопротивляется царапинам (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, экономическая эффективность, и производительность. Here’s why it’s the top choice for tough applications:
- Phenolic Heat Resistance Benefit: Handles 150–200°C continuous use (против. 80–120°C for ABS plastic)—perfect for toasters, Компоненты двигателя, and industrial ovens.
- Bakelite Dimensional Stability: Shrinks only 0.5–1.5% during curing (против. 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 стандарты), making it safe for enclosed spaces like aircraft cabins.
- Cost-Effective Thermoset Value: 20–30% cheaper than PEEK (Высокопроизводительный термопластик) while offering similar heat resistance.
- Phenolic Creep Resistance: Maintains shape under constant stress (НАПРИМЕР., brake-pad backings under pressure), outlasting rubber or plastic alternatives.
Bakelite Chemical Inertness: Сопротивляется маслам, растворители, 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.
Отраслевые приложения & Solutions
| Промышленность | Ключевые приложения | Our Molding Solution |
| Электрический | Phenolic molded switchgear, electrical connector housings, RF terminals | Electrical-grade resin, UL 94 V0 compliance, плотные допуски (± 0,01 мм) |
| Технические приборы | Bakelite cookware handles, toaster bases, steam-iron thermostats | Food-contact approved resin, heat-resistant formulations (200° C.) |
| Автомобиль | Phenolic automotive commutators, brake-pad backings, clutch cylinders | Glass-filled Bakelite, IATF 16949 certified production, insert molding |
| Промышленное | Phenolic industrial bobbins, насосные компоненты, Машино -охранники | High-strength formulations, post-mold machining, chemical-resistant sealants |
| Аэрокосмическая | Phenolic aerospace terminal blocks, avionics housings | Low-emission PF, flame-retardant grades, full traceability |
Тематическое исследование: 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 (АБС) failed UL testing due to poor heat resistance.
Наше решение:
- Выбор материала: Выбрал electrical-grade phenolic molding resin with UL 94 V0 flame rating and high dielectric strength (20 kV/mm).
- Дизайн плесени: 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.
- Оптимизация процесса: Set mold temperature to 180°C, injection pressure to 1,200 бар, and cure time to 45 секунды. Добавлен post-mold tapping for terminal connections.
Результаты:
- The case passed UL 489 тестирование (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?
Когда дело доходит до phenolic resin Bakelite injection molding, Yigu Technology stands out for our deep thermoset expertise, строгий контроль качества, и ориентированный на клиента подход. Here’s why clients worldwide trust us:
- Certified Quality: Our plant holds ISO 9001 (Общее качество) и IATF 16949 (Автомобиль) certifications—ensuring compliance with global industry standards.
- End-to-End Expertise: От in-house Bakelite tool design (using SolidWorks and MoldFlow) to global logistics, we handle every step of your project.
- Быстрое прототипирование: Get functional Bakelite prototypes in 7–10 days (против. 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 (для автомобильной) and UL traceability (for electrical parts) to simplify your compliance process.
Global Reach: Наш global phenolic logistics network delivers JIT (just-in-time) к 40+ countries—reducing your inventory costs.