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A Cost-Effective Approach to Creating Large Silicone Rubber Molds Using Advanced Rigid Polyurethane Foam.

Chil-Chyuan Kuo1,2,3,4, Yi-Qing Lu1, Song-Hua Huang5

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Summary

This study introduces a new method for making rigid polyurethane (PU) foam parts using silicone rubber molds (SRMs). This innovative process improves part quality and significantly reduces manufacturing costs for rapid tooling.

Keywords:
compressive strengthpolyurethane foam componentsrigidsilicone rubber moldsurface hardnesswarpage

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Polymer Chemistry

Background:

  • Rigid polyurethane (PU) foam is essential in various industries for structural, insulation, and protective applications.
  • Conventional PU foam production methods suffer from defects like deformation, voids, and air entrapment.
  • Developing defect-free rigid PU foam parts is a critical industrial research area.

Purpose of the Study:

  • To propose and validate an innovative manufacturing process for rigid PU foam parts using silicone rubber molds (SRMs).
  • To establish predictive models for mold deformation and foam part volume.
  • To optimize the foaming agent to water ratio for enhanced surface hardness and mechanical properties.

Main Methods:

  • Utilized silicone rubber molds (SRMs) for PU foam part fabrication.
  • Developed trend equations to predict SRMs deformation based on wall thickness (R²=0.9951).
  • Established predictive equations for PU foam part volume based on foaming agent weight (R²=0.9824) and surface hardness based on water content (R²=0.7517).

Main Results:

  • Identified an optimal foaming agent to water ratio of 5:1 for maximum surface hardness.
  • Achieved an average Shore O hardness of approximately 75 for the fabricated PU foam parts.
  • Determined that specific water-to-foaming agent ratios (e.g., 1.5g water to 15g agent) minimize internal pores, while 3g water enhances mechanical properties.

Conclusions:

  • The proposed manufacturing process using SRMs effectively produces high-quality rigid PU foam parts with predictable properties.
  • The developed predictive models aid in controlling mold deformation and foam volume.
  • Employing rigid PU foam parts as backing for large SRMs can decrease rapid tooling costs by approximately 62%.