The economicsinvolved in thermoplastic resin selectionale complex' because

the resin price is not usually the most important factor' When a thermoplastic
resin is used for injection molding a closedimensional tolerance end product,
the following engineeringrequirementsareessentialin reducing manufacturing
costs:

c Part geometry needsto be designedto produce molded components with

maximum productivitY.
* A precision mold must be designedand constructed for fast running cycles
and molding the maximum number of cavitiesautomatically'
* It is also important to selectthe best type, capacity,and running conditions
of the injection molding machine'
x Then, it is necessaryto establisheffrcient injection molding processsetup
conditions for the resin being used.
well
It is also essentialthat the molding and maintenance otganizations are
trained, using an up-to-date technical training program provided by a qualified
instructor.
less
Material costs become increasingly significant with higher volume and
critical product requirements.Here, the resin cost representsa high percentage
such
of the molded components finished cost. For example, common items
(faucets, valves,tubing, and shower
as businessmachine housings, plumbing
heads), kitchenware and appliance components (refrigerator liners' washing
machi.r. impellers, and vacuum cleanerhousings) are price sensitiveproducts.
of
For thesemarkets,the resin cost becomesa very competitive businessaspect
manufacturing.

1.2.2 MolecularStructureof PlasticMaterials

polymeric materials are an aggregateof long-chained molecular structures.There
aretwo different states,one o?*hi.h it comprised of high polymer compounds
in the
arranged in a crystalline structure (crystalline polymers) and,the other
for--of flexible molecular chains that are entangled (amorphous polymers)'
However, there is no crystalline plastic material exhibiting solely a crystalline
sections
structure, but rather they have a mixed structure in which crystalline
The ratio of crystalline sectionsis called the
and amorphous sectionscoexist.
polymermolecular
Figure1-5 Amorphous 1-5 and 1-6 show the difference between these
material's crystalliniry Figures
sftucture
families of polymers.

Amorphousmolecules 1.2.3 Acrylonitrile-Butadiene-styrene(ABS)

structure
Crystalline
The ABS resinshavea well balancedsetof propertiesfor molding closedimensio-
nal control articles with an outstanding surfacefinishing, Sood impact resistance,
family
and metal plating characteristics.ABS resins belong to a very versatile
of thermoplastic polymers. They are produced by combining three monomers:
monomers
acrylonitrile, butadiene,and styrene.The chemicalstructure of these
requireseach monomer to be an important component of the ABS Acrylo-
resins'
heat resistance,chemical resistance'and surfacehardness to
nitrile contributes
while
the system.The butadiene contributes toughnessand impact resistance,
the styrenecomponent contributes processibiliry rigidiry and strength.
(sAN)-forms the con-
polymer
Figure 1-6 Semi-crystalline ABS plasticsaretwo-phasesystems.Styrene-acrylonitrile
tinuo-usmatrix phase.The secondphaseis composedof dispersed polybutadiene
molecularstructure
General Properties of ABS
Specificgravity 1.05
Tensilemodulus @ 73'F (Mpsi) 0.3
Tensilestrength @ yield (Kpsi) 5.0
Notch Izod impact @ 73'F (ft-lb/in) 2,50-12.0
Thermal limits Servicetemp. ("F) 167-185
Shrinkage (o/o) 0.4-0.7
T^ ("F) 185-240
Vicat point ("F) L JI

Processtimp. ("F) 410-518

Moldtemp. ("F) 122-L76

Drying temp. ("F) t76-t85

Drying time (h) 2.04.0

particles, which have a layer of SAN grafted onto their surface.The binding
matrix layer of SAN makesthis polymer's two phasescompatible.

The property balanceof ABS is controlled by the ratio of the monomers and by
the molecular structure of the two phases.Stabilizers,lubricants, colorants,and
other additivescan be addedto the system,and while this makesthe production
of ABS very complex, it allows great flexibility in product property design.As a
result of the unique morphology of ABS, hundreds of different products have
been developedand are availablecommercially.

ABSresinsaregroupedinto two major divisions:injection molding and extrusion

grades.The primary differencebetweenthesegradesis their meltviscosiry which
is significantly lower for injection molding resins.within eachdivision of ABS
polymers,therearethe correspondingclassesofgrades.StandardABSgradesare
grouped by impact strength into medium, high, and very high impact grades'
The standard ABS versions are availablein a low surfacegloss,a high surface
gloss,and an ultra-high surfacegloss.SpecialtyABS gradesinclude high heat,
plating, clear,flame retardant, and structural foam grades.

Standardgradesof ABS generallymeet the Underwriter's Laboratories(UL) rat-

ing for slowburning (UL-94 HB). FlameretardantmaterialshaveUL-94V0 at
thicknessesaslow as0.062in and UL-94 5V at thicknessesaslow as0.125 in.Cleat
light transmission of 72o/oanda
-\BS gradesusemethyl methacrylateproviding
hazelevel of 10olo.Alloys of ABS-PVC are availablein high and low glossgrades.
and plating grades.ABS-SMA
-\lloys ofABS-PC areavailablein injection molding
heat resistant alloys are available in injection molding, extrusion, and plating
gradeversions.Alloys of ABS-PAare alsoavailablein injection molding grades.

ABS is an excellentchoice for use in alloys and blends. When the plastics are
combined, the positive featuresof each can be maintained, or even enhanced,
rr.-hilethe negativefeaturesof each can be reduced.ABS-polycarbonate(ABS-
pc) and ABS-polyvinyt chloride (ABS-PVC) are well-establishedalloys.More
recentinnovations haveresultedin ABS-styrene-maleicanhydride (ABS-SMA)
and ABS-polyamide (ABS-PA) alloy products.

ABS offers superior processibilityand appearanceaswell aslow cost,along with

a good balanceof engineeringproperties. Figure 1-7 Portablepower tool housing
 Advantages
* Good impact resistance(toughness)and rigidity properties
* Lowcreep
* Good dimensional stability
* High strength properties
s Metal coatingshave excellentadherenceto ABS
* Transformed by conventional thermoplastic methods
* A light-weight plastic material

Disadvantages and Limitations

* ABS is resistantto acids (exceptconcentratedoxidizing acids),alkalis,salts,
Figure t-8 Faucetchrome platedshell
essentialoils, and a wide range of food and pharmaceutical products. It is,
however,attackedby many solvents,including ketone and ester.
* Lowdielectricstrength
* Onlylow elongation available
* Low continuous servicetemperature
* While the mechanical property of the finished part is not sensitive to
moisture,its presenceduring processingcan causepart appearanceproblems.
Maximum suitablemoisture levelsof 0.2% for injection molding and0.03o/o
for extrusion can be reachedusing a dehumidifying air dryer.

Typical Applications
* Refrigerators:Doors and food liners for the interior surfaceof the refrigerator.
Medium impact extrusion and molding grades,including clear ABS, are
used in crisper pans,breakerstrips, shelves,shelfsupports, evaporatorparts
trays, and kick plates.
Small Appliance Housingsand Power ToolApplicatiors; These include harr
Figure 1-9 Briefcaseexternalcovers dryers, curling irons, blenders, electric can openers, coffee makers, food
processors,electric fans, vacuurn cleaners,electric drills, leafblowers, and
lawnmower decks.
AutomotiveApplications:Instrument panels,armrests,interior trim panels,
seat belt retainers, glove compartment doors, and lift gates.ABS plating
grades are used in wheel covers, grilles, headlight, mirror housings, and
decorativetrim.
e Drain:Waste, vent pipes,pipe fittings, and pool filter housings.
* Telecommunications: Telephonehousings,mobile phones,typewriter hous-
ings, and keyboard keys.
Businessand ConsumerElectronics:Videocassettes,televisions,audiovisual
equipment, computer housings,floppy disks,printers, and copiers.
Householdltens; Countertops, sinks, and tub surrounds, roof mounted air
conditioning units.
Recreational:Motorrycle fairing, sailboats,airplanes,campers,hard-sided
Iuggage,and picnic cooler liners.

Other Applications: Briefcases,cosmetic cases,household packaging, toys'

Figure l-10 Videocassette
housing and photographic equipment.