Two-component injection moulding of thermoset elastomer and rigid thermoplastic

Abstract

This project is a collaboration between the University of Malta and Trelleborg Sealing Solutions Malta. The main aim of this project is to investigate the process parameters which should be optimised to produce rubber to plastic products (a subset of two component technology) with the best possible bond strength between the rigid thermoplastic component and the thermoset elastomer component of the final product. Two-component injection moulding of thermoset elastomer (rubber) and thermoplastic is a new technology that enables the production of components made from those two material types without the use of conventional moulding processes such as over moulding) or post-processes (assembly). However, the moulding material combinations proposed by TSS involve balancing competing temperature processes with the high-performance thermoplastic component being injected from a hot barrel to a cold mould and the reverse for the high-performance engineering thermoset elastomer component. These two competing requirements in the same mould will affect the process itself, making it a rather delicate and unpredictable process without adequate analysis. The project commenced with the proper research and selection of software- based tools that would be used to conduct an in-depth analysis to support the optimisation of the production process. Once the tools were selected, specific equipment and material knowledge was expanded upon within TSS facilities and production, validation testing, materials testing, characterization analyses and finally the optimized process parameters were obtained and shared with TSS in the form of this report.