Our Urea Formaldehyde Resin Injection Molding Services
Unlock cost-effective, high-performance solutions with our Urea Formaldehyde (Uf) Resin Injection Molding услуги. Specializing in thermoset UF process for electrical, Автомобиль, 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, Пользовательский инструмент, and expert engineering to meet your unique needs, making us your trusted partner for all UF plastic molding проекты.
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. В отличие от термопластов, UF resin cures permanently under heat and pressure, forming rigid, dimensionally stable parts. Он подпадает под более широкую категориюamino-plastic injection, known for its balance of affordability and performance.
Key defining traits of this process:
- Thermoset Nature: После вылечения, UF parts cannot be melted or reshaped, ensuring long-term stability in harsh conditions.
- Core Applications: Dominant in sectors requiring electrical insulation and cost-efficiency, such as electronics and household goods.
- Материальная универсальность: Blends with fillers (НАПРИМЕР., alpha-cellulose, glass fibers) to enhance strength or reduce costs.
Below is a breakdown of core terms to clarifyUF definition molding:
| Срок | Описание |
|---|---|
| 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
В Yigu Technology, 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 | Спецификации |
|---|---|
| UF Molding Capacity | До 400,000 единицы/месяц (high-volume urea molding for large-scale projects) |
| Точность | Tight-tolerance UF parts: As low as ±0.1 mm (ideal for electrical components) |
| Инструмент | Multi-cavity UF tools (до 24 полости); in-house toolroom for custom designs |
| Настройка | Insert molding UF, over-molding urea, and secondary ops (НАПРИМЕР., бурение, печать) |
| Прототипирование | Rapid prototyping UF resin: 2-4 day turnaround for functional samples |
| Автоматизация | 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 бар) and mold temperature—critical for replicating precise parts in high volumes. Например, our 24-cavity tool for UF closure caps produces 10,000 units per 8-hour shift, сократить время производства 40% compared to standard 8-cavity tools.
The Urea Formaldehyde Injection Molding Process
АUF 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.
Пошаговый процесс разбивки процесса
- Материал подготовка: Смешивать urea formaldehyde resin (granular or powder) with fillers (НАПРИМЕР., alpha-cellulose filled UF) and pigments (for pigmentable urea resin) to create a homogeneous compound.
- Инъекция: Feed the compound into a heated barrel, then inject it into a mold at high pressure (1500-2800 бар) и температура (160-190° C.).
- Выклятый: Hold the mold closed to allow urea formaldehyde curing—typically 20-60 секунды (cure time UF) at 170-185°C (UF mold temperature).
- Дегазация: Используйте degassing urea mold system to remove trapped air, preventing bubbles in parts like electrical housings.
- Демольд: Eject the cured part. Для сложных дизайнов (НАПРИМЕР., snap-fit connectors), Мы используем BMC-UF compression-injection hybrid technology to improve mold filling.
- Пост-обработка: Необязательный post-cure urea (120° C для 30 минуты) для повышения твердости, or secondary ops like drilling or printing.
Key Thermoset Injection Parameters for UF
| Параметр | Типичный диапазон | Влияние на качество части |
|---|---|---|
| UF Mold Temperature | 160-190° C. | Higher temps speed curing; lower temps reduce shrinkage |
| Clamp Pressure UF | 1500-2800 бар | Ensures full mold filling (critical for tight tolerances) |
| Cure Time UF | 20-60 секунды | Shorter times boost output; longer times improve strength |
| Injection Speed | 50-100 мм/с | Faster speeds reduce cycle time; slower speeds prevent flash |
Urea Formaldehyde Resin Materials: Оценки & Характеристики
We offer a diverse range ofurea formaldehyde resin оценки, each formulated to match specific application needs—from electrical insulation to food-contact safety. All materials meet global standards (UL, Rohs) and prioritize sustainability (НАПРИМЕР., low-formaldehyde variants).
Material Grades & Их использование
| Материал | Filler/Additive | Ключевые свойства | Target Applications |
|---|---|---|---|
| Electrical-Grade UF | Glass-filled urea (20%) | Отличная электрическая изоляция, Пламя-возобновляющий | UF electrical housings, wiring devices |
| Low-Formaldehyde UF | Alpha-cellulose filled UF | <0.1% formaldehyde emission, экологически чистый | Household UF tableware, children’s products |
| Food-Contact UF | Никто (чистый) | FDA-совместимость, нетоксичный | 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 |
Сравнение производительности материала
| Свойство | Electrical-Grade UF | Low-Formaldehyde UF | High-Flow UF |
|---|---|---|---|
| Твердость (Шор d) | 75-85 | 70-80 | 68-78 |
| Теплостойкость | Up to 130°C | До 120 ° C. | Up to 115°C |
| Электрическая изоляция | 10⁴ oh · cm | 10¹³ Ω·cm | 10¹² Ω·cm |
| Расходы (за кг) | $2.80-$3.20 | $3.00-$3.50 | $2.60-$3.00 |
Surface Treatment for Urea Formaldehyde Parts
To enhance aesthetics and durability, Мы предлагаем рядПоверхностная обработка options for UF parts. These treatments address common needs like scratch resistance, глянец, и брендинг.
| Тип лечения | Выгода | Идеально подходит для |
|---|---|---|
| UF Part Polishing | Создает гладкий, 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 (до 4 цвета) | Branded buttons urea resin, распределительный устройства |
| Texture Etching Urea | Non-slip or decorative textures | Industrial UF handles, инструментальные схватки |
| Edge-Sealing UF | Prevents moisture absorption | Outdoor UF parts, bathroom accessories |
Например, нашsublimation 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, Высокопроизводительные приложения. Its advantages over other thermosets (НАПРИМЕР., melamine, эпоксидная смола) and thermoplastics (НАПРИМЕР., АБС) ясны:
- 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.
- Размерная стабильность: 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: Более короткое время цикла (20-60 секунды) than most thermosets—ideal for high-volume runs like closure caps (400k units/month).
- Recyclable Flash UF: Scrap material (вспышка) can be ground and reused (до 15% of total compound), reducing waste and costs.
Advantage Comparison: UF vs. Melamine-Formaldehyde (MF)
| Преимущество | Urea Formaldehyde (Uf) | Melamine-Formaldehyde (MF) |
|---|---|---|
| Расходы (за часть) | Ниже (15-25% меньше) | Выше |
| Время цикла | Быстрее (20-60 sec) | Помедленнее (30-120 sec) |
| Электрическая изоляция | Начальство | Хороший |
| Теплостойкость | Up to 130°C | Up to 200°C |
| Food-Contact Safe | Only FDA-approved grades | Большинство оценок |
Industry Applications of Urea Formaldehyde Parts
UF resin molding обслуживает широкий спектр отраслей, driven by its cost-efficiency and electrical insulation properties. Below are the most common use cases:
| Промышленность | Приложения | Key Material Grade |
|---|---|---|
| Электрический & Электроника | UF electrical housings, переключатели, wiring devices | Electrical-Grade UF |
| Технические приборы | Knobs, управляющие панели, dryer components | Pigmentable Urea Resin |
| Автомобиль | Внутренняя отделка, корпуса разъемов, Дверные ручки | High-Flow UF |
| Household | Closure caps, tableware (Food-Safe), toilet seat UF | Low-Formaldehyde/ Food-Contact UF |
| Промышленное | Ручки, Машино -охранники, Крышка клапана | Glass-filled Urea |
Например, в автомобильной промышленности, нашhigh-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%.
Тематические исследования: Our UF Injection Molding Success Stories
We’ve helped clients across industries overcome production challenges with tailoredUF resin molding решения. Here are three standout cases:
Случай 1: UL-Listed UF Switchgear Housing
- Клиент: A leading electrical equipment manufacturer.
- Испытание: Производить 100,000 switchgear housings that meet UL 94 V0 flame-retardant standards and ±0.1 mm tolerance for component fit.
- Решение: Used electrical-grade UF with glass filler; optimized clamp pressure UF (2500 бар) и UF mold temperature (180° C.) для точности.
- Результат: 99.8% Без дефекта ставка; UL listing obtained in 4 недели; production cost 20% lower than client’s previous supplier.
Случай 2: Cost-Down UF Lid for Household Jars
- Клиент: A global food packaging brand.
- Испытание: Reduce costs for 500,000 monthly UF closure caps without sacrificing durability.
- Решение: Switched from pure UF to alpha-cellulose filled UF (30% filler); implemented 24-cavity UF tools (up from 12-cavity).
- Результат: Cost per lid reduced by 18%; hardness maintained (Шор d 75); Временная скорость доставки 99%.
Случай 3: High-Gloss UF Toilet Seat
Результат: Product passed 10,000 scratch tests; UV resistance rating of 4+ (no fading after 2 годы); удовлетворенность клиента 95%.
Клиент: A sanitary products company.
Испытание: Create a high-gloss toilet seat UF with scratch resistance and UV stability (for bathroom sunlight exposure).
Решение: 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:
Надежность: 24/7 UF tech support (average response time <2 часы); 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 (НАПРИМЕР., tight-tolerance parts, пользовательские цвета).
Гарантия качества: Iso 9001 urea plant with in-house testing labs (tests for hardness, изоляция, Пламя сопротивления); 99.5% average defect-free rate.
Экономическая эффективность: Competitive UF pricing (10-15% below market average) thanks to automated lines and recyclable flash usage; Нет скрытых сборов.
One-Stop Service: From DFM (Дизайн для производства) for UF molding to global logistics—we handle every step, saving you time and hassle.