POLYMER AND CERAMIC BDB 4063

CHAPTER 1

INTRODUCTION

 Component: Household Application ( Blender)

Blender is make from polymer plastics. In plastics have two type Thermosets and

Thermoplastic. In this case, thermosest type me choice is Melamine formaldehyde (MF)

thermosets.

1.1. What is Melamine formaldehyde (MF) thermosets

Melamine formaldehyde (MF) also react further at room temperature .This showns itself in a

decrease of flowability ,it can be so formulated that they are suitable for tropical use. The-

requisite for manufacture of molded articles which do not subquently shrink is that molding

1

POLYMER AND CERAMIC BDB 4063

compounds must be dry. MF molding compounds absorb less moisture when immersed in

cold water than UF moldings. However the nature of the filler has a large effect. Wood

flour,cellulose and textile reinforcements are poorer than asbestos .mica and textile glass

material.

melamine formaldehyde (also shortened to melamine) is a hard,thermosetting plastic material

made from melamine and formaldehyde by polymerization. In its butylated form, it is

dissolved in n-butanol and xylene. It is then used to cross-link with alkyd,epoxy, acrylic,

and polyester resins, used in surface coatings. There are many types, varying from very slow

to very fast curing. It was initially discovered by William F. Talbot.

These thermosetting plastics, also called amino resins because they are produced by the

reaction of amines, or compounds bearing the amino group (-NH2), with formaldehyde, are

clear and colourless, a distinct advantage over the phenolics. They also have better hardness

and tensile strength than phenolics, but their impact strength and moisture resistance are

lower. Ureas have lower hardness, heat resistance and moisture resistance than melamines.

Amino resins are used in the fabrication of industrial and decorative laminates, adhesives,

protective coatings, paper manufacture, and moulding compounds. Melamine is one of the

thermosetting plastics that can be made in unlimited colours. Articles fabricated from

melamines are rigid and have one of the hardest surface finishes of any plastic material.

Because of this they are widely used for the production of decorative laminates, which are

usually assembled from a core of phenolic resin-impregnated paper and a melamine

impregnated overlay sheet.

Figure:Idealized structure of melamine formaldehyde

2

POLYMER AND CERAMIC BDB 4063

1.2. Melamine formaldehyde (MF) thermosets characteristics:

-high surface hardness and scratch resistenace

-high surface gloss.

-high resistance to creep

-resistant to heat(up to 250 c/482 F for special grades),

-resistant to moisture

-not suitable for continuous contact with boiling water,

-high shrinkage as for Urea Formaldehyde(UF) molding compounds,

1.3. Melamine formaldehyde (MF) thermosets application:

-table tops, dinnerware, protective coatings, adhesives, lighting fixtures, heavy duty electrical

equipment, decorative laminates, housings,basins,grips ,screw caps, installation

material,switches and spark arresting chambers.

3

POLYMER AND CERAMIC BDB 4063

Construction material

Melamine resin is the main constituent of high-pressure laminates, such

as Formica and Arborite, and of laminate flooring. Melamine-resin tile wall panels can also be

used as whiteboards.

Melamine & LEED: Phenol formaldehyde (PF) is used typically used as the binder / resin in

hard-surface countertop materials, such as those used in lab desks. Melamine formaldehyde

(MF) is a related compound used in plastic laminate and overlay materials. Formaldehyde is

more tightly bound in PF and MF than it is in Urea Formaldehyde, reducing emissions. LEED

v2.2's EQ Credit 4.4 precludes the use of Urea-Formaldehyde, but allows the use of Melamine

Formaldehyde.

4

POLYMER AND CERAMIC BDB 4063

CHAPTER 2

MELAMINE FORMALDEHYDE MANUFACTURE AND PROCESSING

TECHNIQUES

2.1.Chemical Compound

Melamine formaldehyde(MF) are resistent to water(hot and cold), weak alkaline solution,

alcohols,wsters,ether,benzene,petrol,mineral oil,fats; theyare resistant to weak acids under

certain conditions but not resistent to strong acids and strong alkalis.

Melamine can be manufactured from dicyandiamide, hydrogen cyanide, or urea. Modern

commercial production of melamine typically employs urea as a starting material. Urea is

broken down to cyanuric acid, which then can be reacted to form melamine. Its most

important reaction is that with formaldehyde, forming melamine-formaldehyde resins of

high molecular weight. These compounds form under the influence of heat and then become

fixed into an insoluble and infusible mold; this process is known as thermosetting. Melamine-

based thermoset materials contain cross-linked polymers, which make the fixed molds strong

and durable.

The mechanism of resinification and cross-linking is similar to that observed for urea-

formaldehyde and involves methylol-amine and methylol-methylol condensations.

5

POLYMER AND CERAMIC BDB 4063

Cellulose Filled MF is a subcategory of Melamine formaldehyde. The additative is added

during the manufacturing process. Its elastic modulus ranges from 1100 to 1400 MPa. Its

tensile strength ranges from 5000 to 13000 MPa at break. Its flexural strength ranges from

9000 to 16000 MPa. Its compressive strength ranges from 33000 to 45000 MPa. Its Izod

Impact strength ranges from 0.2 to 0.4 J/cm. Its elongation at break ranges from 0.6 to 1 %.

Its hardness ranges from 115 to 125 Rockwell M. Its specific gravity ranges from 1.47 to

1.52. Its coefficient of thermal expansion ranges from 40 to 45 x 10-6/°C. Its molding

pressure ranges from 8 to 20 Mpa

Figure: urea-formaldehyde

Figure: Reactions in the synthesis of formica

6

POLYMER AND CERAMIC BDB 4063

Figure :Structure of monomer of melamine-formaldehyde resin

2.2. Properties of Melamine Formaldehyde (MF)

Thermoset

Melamine Formaldehyde (MF), cellulose filled

Property Value in metric unit Value in US unit

Density 1.55 *10³ kg/m³ 96.8 lb/ft³

Modulus of elasticity 12 GPa 1800 ksi

Tensile strength 65 MPa 9500 psi

Elongation 0.6 % 0.6 %

Flexural yield strength 140 MPa 20000 psi

Compressive strength 240 MPa 35000 psi

Thermal expansion (20 ºC) 29*10-6 ºCˉ¹ 16*10-6 in/(in* ºF)

Maximum work temperature 150 ºC 300 ºF

Table of Properties of Melamine Formaldehyde (MF)

7

POLYMER AND CERAMIC BDB 4063

Thermosetting Materials

Tensile Strength,

psi (ASTM D-

638)

Elongation, % (ASTM

D-638)

Tensile Modulus,

105 psi (ASTM D-

638)

Compressive Strength, psi, (ASTM D-

695)

Flexural Yield

Strength, psi,

(ASTM D-790)

Hardness**

Melamine-formaldehyde (moulding compounds)

5,000-13,000

0.3-0.9 11.0-24.0 20,000-45,0009,000-23,000

M110-M125

Table of Typical Range of Mechanical Properties of Thermosetting Plastics (Filled or

Reinforced)

Thermosetting Material

Burning Rate (Flammability), in./min., (ASTM

D-635)

Coeff of Therm Exp.

1005/°F

Resistance to Heat

(continuous), °F

Water Absorption, % (ASTM

D-570)

Chemical Resistance*(room

temperature)

Melamine-formaldehyde

Very slow burning, self-ext or nonburning

0.8-2.5 210-400 0.08-0.80 May resist or undergo slight attack by weak acids and alkalis but decomposes in strong acids and alkalis.

Table of General Properties of Commercial Thermosetting Plastics (Filled or

Reinforced)

8

POLYMER AND CERAMIC BDB 4063

Thermoset materials do not dissolve, and only swell if they interact with solvents. Many

thermoset materials do not swell appreciably in contact with any solvent, but some of the

compounding ingredients may be leached out.

2.3 Advantage & Disadvantage of Melamine Formaldehyde (MF)

The are have several advantange and disadvantage :

Advantages:

-good dielectric properties

-better resistance to creep

-grades filled with MF molding compunds.

-less shrinkage

-less tendency to stress crack formation when exposed to moisture and heat,

-lower cost.

Disadvantages:

-Inferior to Phenolic in dimensional stability in hot dry conditions. 

-More expensive than Urea or Phenolic. 

-Limited resistance to concentrated acids and alkalies

9

POLYMER AND CERAMIC BDB 4063

2.4 PROCESSING TECHNIQUES

Properties of MELAMINE & UREA (Amino Moulding Powders)

These thermoset materials give a unique combination of moulded properties which are

unmatched by any other plastic raw materials in the same price range, making them ideal for a

wide range of applications, particularly in the domestic field. Of especial importance is their

ability to not soften or melt on heating as thermoplastics do, this being a result of irreversible

cross linking of the polymer that takes place during the moulding process (compression or

injection) under conditions of heat and pressure.

UREA

Urea formaldehyde (UF) materials combine a virtually unlimited range of colours and

excellent colour retention with good electrical properties, solvent resistance, high flame

retardance, high rigidity, surface hardness and scratch resistance and permanent anti-static

properties. 

Uses: 

Electrical components, closures, toilet seats

MELAMINE

The melamine formaldehyde (MF) materials give mouldings with a superior surface

performance to UF materials. Their excellent stain resistance and low formaldehyde

extraction properties make them suitable for food contact applications such as table and

kitchenware whilst their greater heat resistance makes them ideal for such items as ashtrays. 

10

POLYMER AND CERAMIC BDB 4063

Uses: 

Tableware, Kitchenware, Knobs and components for white goods, electrical accessories

PHENOLIC (Bakelite)

Phenolic (Bakelite) moulding compounds are based on a phenol-formaldehyde resin

processed with inert fillers, cross-linking agents, accelerators, and pigments or dyestuffs.

They can be readily tailored to suit specific property or mouldability requirements. They are

low cost thermosetting materials capable of being moulded under heat and pressure to give

flow then permanent setting to a desired form. 

Phenolic mouldings have good electrical properties, heat resistance, moisture resistance,

dimensional stability, high surface hardness and mechanical strength. 

Uses: 

Electrical components, knobs and components for white goods, meter parts, automotive

components, cookware handles and fittings.

Dough (Bulk) Molding Compound

Dough (Bulk) Molding Compound (DMC sometimes referred to as Bulk Moulding

Compound usually abbreviated to BMC) is a thermoset plastic resin blend of various inert

fillers, fiber reinforcement, catalysts, stabilizers, and pigments that form a viscous, putty like,

compound for compression or injection molding. DMC is highly filled and reinforced with

short fibers. Glass reinforcement represents between 10% and 30%, with glass length

typically between 1mm and 12.5mm. 

Depending on the end-use application, compounds are formulated to achieve close

dimensional control, flame and track resistance, high dielectric strength, corrosion and stain

resistance, superior mechanical properties, low shrink, and color stability. Its excellent flow

characteristics and electrical and flame resistant properties make DMC well suited to a wide

variety of applications requiring precision in detail and dimensions. The material is available

in a wide variety of colors, and can tolerate powder-coat or water-based paint. 

Uses: 

Electrical components, white goods components, hifi components, cookware,

telecommunication components, lighting components.

11

POLYMER AND CERAMIC BDB 4063

Sheet Molding Compound

Sheet Molding Compound (SMC) is used in compression molding, often of larger parts,

where higher mechanical strengths need to be achieved. Glass reinforcement is between 10%

and 60%, and glass length is slightly longer than DMC, between 12.5mm and 25mm. 

As with DMC, thermoset SMC is a mixture of polymer resin, inert fillers, fiber reinforcement,

catalysts, pigments and stabilizers, release agents, and thickeners. Manufacture of SMC is a

continuous in-line process. The material is sheathed both top and bottom with a polyethylene

or nylon plastic film to prevent auto-adhesion. The paste is spread uniformly onto the bottom

film. Chopped glass fibers are randomly deposited onto the paste. The top film is introduced

and the sandwich is rolled into a pre-determined thickness. The sheet is allowed to mature for

48 hours. 

SMC can be molded into complex shapes. High mechanical properties and excellent surface

appearance make SMC ideal for automotive Class ‘A’ body panels, high-strength electrical

parts, business equipment cabinets, personal watercraft, and various structural components. 

Uses: 

Automotive components, mass transit components, building and construction components.

Lighting components.

MELAMINE FORMALDEHYDE AMINO RESINS

ATEC has conducted extensive R & D work to develop and perfect numerous Melamine

Formaldehyde Amino Resin formulations and owns the related technologies, (process Know-

How /design /engineering) to manufacture various liquid and powder resin grades. ATEC’s

patented melamine formaldehyde resin grades are: 

ATMFORM 102 L/102 P

These are liquid and powder grades of unmodified Melamine Formaldehyde powder Resins

suitable for impregnation of base /decorative papers and overlay in the manufacture of high

pressure decorative laminates, low pressure melamine surfaced wood boards /panels etc.

Typical Powder Resin Specifications are :12

POLYMER AND CERAMIC BDB 4063

Appearance : White free flowing powder

Bulk Density g /cc (minimum) : 0.55

Volatiles   : 3

pH (50 % soln.), 25°C   : 9.3 ± 9.7

Viscosity : 30 ± 3

Dilution in water   : Up to 25 % solids

Gel time 50 % soln., @ 150°C : 260 ± 20 seconds

Free formaldehyde %    : 0.6 ± 0.05

ATMFORM 105 L 105 P

These are liquid and powder grades of precatalysed Melamine Formaldehyde Resin for the

said end use application. Typical specifications of powder (ATMFORM 105 P) Resin are : 

  Appearance : White free flowing

powder

  Bulk density g /cc (Minimum) : 0.55

  Volatiles 105 °C /1 hr, % (Max.) : 3

  pH (50 % soln.), 25°C : 8.8 + 0.2

  Viscosity OF 50 % soln. (25°C), Cps : 30 ± 3

  Dilution in water : up to 25 % solids

  Water tolerance (50 % Soln.)% : 120 + 20

  Gel time 50 % Soln.,150°c spatula

method (sec.)

: 80 + 10

   Free formaldehyde %     : 0.6 ± 0.05

13

POLYMER AND CERAMIC BDB 4063

ATMFORM 108 L /108 P

ATMFORM 108 P is a powder Melamine Formaldehyde Resin used for glazing of Amino

moulded articles viz. Melamine based crockery. The same resin can be used for the

impregnation of overlay papers also. Basically ATMFORM 108 P is used in powder form for

glazing application, while it needs to be reconstituted into solution form by dissolving in

water for impregnation of papers. Typical specifications of powder (ATMFORM 108 P) are :

  Properties   Specification  Appearance : White free flowing powder  Bulk density (g/cm³) : Min 0.400  Free formaldehyde (%) : 0.600 ± 0.10  Volatiles (105°C/1 hr ) % : > 4  Gel time at 150 °C

(seconds)50 % solutions properties

: 25-45.

  Appearance : Water white to slightly hazy liquid free from suspended impurities and dissolved particles

  Water tolerance : 50-120  pH at 25°C : 7.4-8.4

  Viscosity at 25°C : 25-35 Cps

14

POLYMER AND CERAMIC BDB 4063

CHAPTER 3

DISCUSSION AND CONCLUSION

3.0 Discussion and Conclusion

For discussion in chemical Properties Melamine formaldehyde molded material are

resistent to water (hot and cold), weak alkaline solutionsi and in MF molding compound are

available as powder ,fibers, chips or granules. In this thermoset it have advantage and

disadvatages and for that wa must develop for green technology for earth save.

Melamine formaldehyde is a thermosetting plastic (or thermoset) that strengthens as it

is heated during its preparation. Once set, it cannot be remolded or set to form a different

shape. Melamine formaldehyde plastics retain their strength and shape, unlike other types of

thermoplastics that soften with heat and harden when cooled (such as acetate, acrylic and

nylon)

15

POLYMER AND CERAMIC BDB 4063

REFERENCES

1. .Plastics for Engineers Material,Properties, Applications, Hons Domininghaus,

Hanser Publishers , New York, 1993.

2. .Guide to Plastics, by the Editors of Modern Plastics Encyclopedia, McGraw Hill,

Inc., New York, 1970.

3. .Fourth Edition Plastics Technology Handbook, Manas Chanda, Salil K. Roy, CRC

Press, U.S, 2007.

4. Third Edition PLASTICS material and Processing , Strong ,A.Brent ,

PearsonEducation Ltd,US,2006

16