Phenolic Resins and Phenolic Molding Compounds Greg Spaeth Project Engineer, Materials Engineering Laboratory Plastics Engineering Company Presented at 2013 SPE Thermoset Division TOPCON
Feb 23, 2016
Phenolic Resins and
Phenolic Molding Compounds
Greg SpaethProject Engineer,
Materials Engineering LaboratoryPlastics Engineering Company
Presented at 2013 SPE Thermoset Division TOPCON
Phenolic Resins
Phenolic resins are synthesized in a pressure vessel by repeatedly linking phenolic monomers
with aldehyde chemicalsTypically phenol and formaldehyde
Cresol Cashew nutshell oil
Furfural
Process variations can result in a assortment of resin structures each
demonstrating a wide range of properties
Other phenols include
Another aldehyde used
There are Two Types of Phenolic Resins
NovolacMolar excess of phenolRequire an external curing agent
Usually hexamethylenetetramine or “Hexa”Two Stage
Two year shelf life
ResolTypically there is a molar excess of formaldehydeDo not require an external curing agentSingle StageSix month shelf life
Phenolic Molding Compounds
Phenolic Molding CompoundsPhenolic Molding Compounds are produced by compounding
various fillers with Phenolic Resin
Typical Formula
50 % Phenolic Resin, resol or novolac 45 % filler
5 % colorants and lubricants
Woodflour
Glass FibersCotton
Carbon Fibers or graphite powder
Minerals, talc, clay, ATH, etc.
Carbon BlackZinc Stearate
The Oil and Natural GasMining Process
as a Case Study forPhenolic Materials
A well begins by drilling a large diameter hole extending below the fresh water
A surface casing is inserted to isolate fresh water and support the blow out preventer
Cement is pumped into the casing
The cement is forced out of the casing and up the well hole sealing of the aquifer
Wiper Plugs and Darts
Phenolic Core
Over molded rubber shell
Easy drill out with small debris
The molded phenolic core provides superior strength and rigidity to enable the wiper plug to withstand the high pressures involved in forcing hundreds of cubic feet of concrete through the well casing
Why Phenolic Molding Compounds?
High Modulus provides stiffness and stability for the darts mandrel core and tighter griping for the elastomer wiper segments
Heat resistance allowing plugs rated for use at 400ºF
The wiper plug is then drill out and the production well is drilled.
Production casing is lowered It takes more than 350 casings weighing more then 85 tons to case a 10,500 foot well
Cement is once again pumped into the well
Again using a wiper plug the cement is force back up the well securing the casing
Fracturing the well then begins by lowering a perforation gun down the well casing
Small shaped explosives blast holes through the casing, cement, and into the formation
Fracturing fluid is pumped into the well
The fluid under extreme pressure causes the formation to fracture
Fracturing fluids varies among regions and well types, but typically consists of water (90+%) proppant (9%) and chemicals (<2%)
Resin Coated Proppant Sand
Resin Coated Proppant Sand
Once the fracturing fluid is removed, the phenolic resin coated sand remains behind and works as a prop to keep the fissures from sealing on release of pressure
Phenolic’s high modulus and excellent heat and creep resistance resists fracture under pressure as proven in industry “Conductivity test”
Why Phenolic Resin?
Chemical Resistanceharsh chemicals found down hole can attack various proppantincluding ceramic proppant
Why Phenolic Resin?
Curable ProppantEnables the proppant to remain in place in wells with high pressure flow
The now fractured portion of the well is sealed off using fracturing ball
Fracturing Balls
Fracturing Balls
Customizable formulations allowing a specific gravity range of 0.8 to 3.5+
Phenolic Balls offer an excellent combination of chemical and heat resistance with superior tensile and compressive strength compared with other plastic balls.
Why Phenolic Molding Compound?
The perf gun is again lowered and detonated
Again fracturing fluid is pumped into the well to fracture the new section of the well while the already fractured section is isolated by the frac ball
The perf gun is again lowered and detonated
Fracturing Balls
Perforation and well fracturing is repeated as often as needed
Once fracturing is complete the balls are usually drilled or floated out
Surface equipment is put in place
Well begins production
Valve Components
Valve Components
A phenolic back-up ring allows internal pressure to anchor the seat within the valve body and prevents seat walking
Non-collapsible, stretch resistant, blow out proof, field replaceable
Non-collapsible, stretch resistant, blow out proof, field replaceable
Why Phenolic Molding Compounds?
Strength, rigidity, dimensional stability, creep resistance
Chemical resistance and high hardness
Provide valve components that resists corrosive environments and do not deform under pressure allowing for repeated ball sealing
Corrosive coatings forStorage tanks, semi tank trailers, railroad tank cars, fans blowers, and fin tube coils
Other Applications
Binder forFriction pads, brake pads, grinding wheels, plywood and particle board
Wear ResistanceGas meter valves, pump seals, caster wheels
Dimensional Stability &Thermal PerformanceBrake pistons, transmission parts, electrical motor brush cards
Electrical insulationterminal strips, commutators, capacitor cans and caps
Offshore Applications
Why Phenolic Resin?
Superior Creep ResistanceStrength and stability under load
Low weight high strength and modulusStrength and rigidity
Chemically ResistantHarsh marine environment
Excellent flammability resistance and low smoke and toxicity Increased level of safety
High carbon and char yieldRetains level of strength and integrity should fire break out
Chemical Resistance
Phenolic Properties
Transmission oil,150ºC (302ºF)
Salt water, 65ºC (150ºF)
Beach, 65ºC (150ºF)
Unleaded gasoline, 22ºC (72ºF)
E85 Unleaded gasoline, 22ºC (72ºF)
SAE 30 Motor oil, 150ºC (302ºF)
Propylene glycol, 100ºC (212ºF)
Crude oil, 22ºC (72ºF)
Chemical Resistance
Phenolic Properties
Chemical Resistance
Phenolic Properties
Chemical Resistance
Phenolic Properties
Chemical Resistance
Phenolic Properties
Chemical Resistance
Phenolic Properties
Comparison of Phenolic molding compound to engineering grade thermoplastics
Phenolic Properties
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values
Thermoplastics20% fiber glass filled ABS 20% fiber glass filled Acetal20% fiber glass filled PPA20% fiber glass filled PPS20% fiber glass filled Nylon66
Phenolic Molding CompoundGlass and mineral filledPLENCO 06404 glass and mineral filledPLENCO 02311 general purpose woodflour filled
Hardness
Phenolic Properties
Data for phenolic and PLENCO materials are approximated from E scale
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values
Strength and modulus
Phenolic Properties
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values
Strength and modulus
Phenolic Properties
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values
Compressive Strength
Phenolic Properties
Data for PLENCO materials available from PLENCO.com, all thermoplastic data from matweb.com overview average values
Heat Resistance
Phenolic Properties
Flammability resistance
Phenolic Properties
UL V-0 at 0.5mm
IEC 60695 Glow Wire GWFI and GWFI Rating 960ºC+ at 0.75mm
ASTM E162 Flame Spread 0.85*
*Source: Composites WorldAuthor: Michael LeGault Posted on: 2/14/2013
Post bake
Phenolic Properties
What is it?• Postbaking is a manufacturing step where molded parts are heated in an
oven after being removed from the die.
Why do it?• Dimensional stabilize a part, especially for high temperature applications• Out-gas residual ammonia which is a by product of two stage cure• Improve strength• Sometimes only because the print tells you to
How is it done?• Ramp oven from room temperature to 15ºC below parts initial tg at 5º/min• Ramp oven to desired temperature at 0.5-0.25ºC/min to keep the oven
temperature under the parts instantaneous tg
Do I need to do it?• Many Applications do not require a postbake, only a thorough
understanding of the reasons to postbake will help you answer this question
Thank You
Questions?
Greg SpaethProject Engineer,
Materials Engineering LaboratoryPlastics Engineering Company
Presented at 2013 SPE Thermoset Division TOPCON