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Service temperature
Engineering Polymers
High-Performance
Polymers (HPP)
(TI1 > 150C)
Engineering
Polymers (ETP)
(TI1 90 150C)
Basic
Polymers
LCP
Vectra /Zenite
PPS
Fortron
PCT
Thermx
PET
Impet
PBT
Celanex
PBT Alloy
Vandar
TPC-ET
Riteflex
POM
Hostaform/Celcon
UHMW-PE
GUR
Amorphous
LFRT
Celstran, Factor
Compel
CFR-TP
Celstran Tapes,
Rods and Profiles
Partially crystalline
Melting range rather than sharp melt point and very low heat
of fusion.
High chain continuity, ordered molecular structure in both solid
and melt phase.
Flows extremely well under shear within the
melting range.
Inherently flame resistant.
High heat deflection temperatures.
Reinforcement reduced anisotropy increases load bearing
capability.
Random Coil
Melt
Extrusion
Solid State
Extended chain Structure
High Chain Continuity
High Mechanical Properties
Inherent Property Anisotropy
2013 Celanese LCP-007 AM 10/13
Lamellar Structure
Low Chain Continuity
Lower Mechanical Properties
320
300
T resin (T130)
280
J resin
(30% GF)
Ei resin (E130i)
260
C resin (C130)
240
A resin (A130)
L resin (L130)
220
200
1980
1985
1990
1995
2000
2005
2010
350
330
310
290
Vectra S135
PPA
270
PPS
Vectra E130i
PA HTN
PA 46
250
PCT
Vectra A130
230
210
240
260
280
300
320
340
360
380
Melting Temperature C
Filler Reinforcement
Effect(s)
Fiberglass
Carbon fiber
Mixed fillers/fibers
Mineral fillers
Graphite flake
Carbon black
Electrostatic dissipation
Proprietary fillers
Improved platability
Pigments
Color concentrates
A115
A130
A150
Carbon Fiber
A230 D3
Fiber / Filler
A430 FDA
A435 FDA
E130i
E150i
E480i
E130G
S135
E440i
E 463i /E471i
E473i
E488i
S471
S475
E540i
Mineral
Graphite
A625
Conductive
A700
A725
A230-D3
J540
S540
S625
E820i Pd
E830i Pd
E840i LDS
Plateable
Unreinforced
A950
V140
V143 XL
V143 LC
HDT Increases
2013 Celanese LCP-007 AM 10/13
Vectra E130i
PPS
PCT
PPA
PET FR
50
100
150
Dimensional Stability
As molded
SMT @ 260C
3.5
3
2.5
2
1.5
1
0.5
0
Vectra E130i
PPS 40GF
HTN 35GF V0
10
Water Absorption
40000
LCP GF30
35000
LCP GF30
PPS GF40
PA9T GF33
PA9T GF33
PA6TGF30
PA46 GF40
30000
25000
20000
15000
10000
5000
0
40000
PPS GF40
PA6TGF30
20
40
PA46 GF40
60
Time (hours)
80
100
35000
30000
25000
20000
15000
10000
5000
0
20
40
60
80
Time (hours)
100
PA 6T GF30FR
PA 46 GF30FR
Condition:
40C; 95%RH; 96 hrs;
IR Reflow @ 265C
11
Automotive
E&E
Technology
MID/LDS
High
Performance
Connectors
LCP
Cookware
Electronic
Packaging
Medical
Tech Fibers
12
Lead-free soldering
(ROHS and WEEE)
Material
Requirements
Higher heat
resistance
High flow
Improved flatness
Miniaturization
(complex, thinner)
Stronger weldlines
Higher frequency
Electrical properties
V-0 Halogen free
Agency compliance
13
High Temperature
Halogen-Free Polymers
14
Molding
Processing Recommendations
Drying
General Processing Guidelines
Equipment
Additional Considerations
15
Molding
Drying Conditions
LCP resins must be dried before molding to reduce the possibility
of hydrolytic degradation.
Dry LCP at 150 - 170C for a minimum of 6 hours; overnight
16
Molding
Processing Temperatures
Processing Temperatures in C
1
2
3
4
D
M
W1, W2
A Series
Ei Series
S Series
270 to 280
315 to 325
330 to 350
275 to 285
315 to 325
340 to 360
280 to 290
325 to 335
345 to 365
285 to 295
335 to 345
355 to 370
290 to 300
335 to 345
355 to 370
285 to 295
335 to 345
360 to 370
80 to 120
80 to 120
80 to 120
17
Molding
Molding Variables Injection Pressure.
Molding by position transfer or pressure transfer is preferred using high injection
speed. Data acquisition equipment and pressure transducers in the tool to monitor
process is recommended
"E130i
Lot 1HMV"
Lot 2
"E130i"
Injection pressure
Holding pressure
PN ~ PSp
Back pressure
Screw speed
ns = vs/d
Vs (periph. velocity of screw) ~ 0.1 to 0.3 m/s
Injection speed
Very high
Nozzle
1.5
1.55
1.6
1.65
1.7
1.75
1.8
1.85
1.9
18
Molding
Molding Variables Injection Pressure
Melting range rather than sharp melt point. Low heat of fusion results in very fast
cure and cycle times. Typical cure time is a few seconds with a cycle time range
of 4 to 13 seconds for small part molding (depending on cavitation).
19
Molding
Molding Variables
Injection Speed vs. Flow Length (0.1 mm Test Bar)
Injection speed is a function of shear
30
Vectra E130i
25
20
15
10
PPS 40% GF
5
0
0
50
100
150
200
250
20
Molding
Injection Molding Equipment
Reciprocating screw injection molding machines:
Barrel utilization 10-35% of machine capacity. For complex/critical designs increase barrel
utilization between 20-50% of machine capacity. (Note: short consistent SRT is critical)
Screw design guidelines:
Nozzle tip:
Reverse taper, small orifice diameter, 1.5 to 2.5 mm depending on grade and material selection
Clamp force 2.0 to 3.5 tons per square inch cavity area depending on wall thickness
21
Molding
Purging
Switching from another material:
Purge the material out of the machine with low MFI HDPE, then raise temperatures for
molding Vectra LCP.
Begin molding when material is flowing cleanly from the nozzle.
Switching between grades of Vectra LCP:
One grade of Vectra LCP can be used to purge another without using a purge compound. When the
new grade is flowing cleanly, begin molding.
22
Molding
Regrind
Extremely stable to reprocessing, 50% regrind UL listing. (Seven pass regrind study)
Grinding process
Hot feed
Slow speed, shear cutter
Close tolerance cutter*
Closed loop system preferred
23
Molding
Key Processing Tips
Dry Vectra LCP grades < .01 percent and use on-line dehumidified hopper dryer.
Use close tolerance screw and barrel.
Inspect check valve for wear on a routine basis.
Use press with good process control.
Data acquisition and pressure transducers are best.
Use independent nozzle heater control.
Decompression < 3mm none is preferred.
Do not use sprue break.
Use fast injection speed and moderate screw speed.
Verify melt temperature is within the suggested range.
24
Part Design
25
Part Design
Recommended Runner Design for Vectra LCP
Traditional Design
Larger gates and runners
area easier to fill
Full round runner is best
Cold-slugs wells
Straight geometry
Venting added before first shots
Recommended Design
Smaller is better
Modified Trapezoid is best
Remove cold-slug wells
Curvy geometry
Venting of the cavity added after first
shots is critical and will lower the
pressure to fill the cavity
Why? Insulated by one piece of steel vs. two (easier to control temperature).
It also removes potential errors by only cutting one half of the tool.
2013 Celanese LCP-007 AM 10/13
26
Part Design
Runner Sizes
Traditional Runner Design
Runner sizes started around 0.200
(5.1 mm)
Large runner sizes with E-Series
cause too much pressure loss in the
runner system. When the material
reaches the part, theres not enough
pressure to push it into the intricacies
of the design.
27
Part Design
Runner Design
Traditional Runner
Imbalanced flow, doubled cavitation
adds shear
Improved Solution
Balanced flow, improved quality
28
Part Design
Venting Design
Since LCP has very low shrinkage, polish vent lands in cavity, polish runner and
29
Part Design
Gate Design
Typical runner/gate:
Conventional cold runner
Hot runner with cold sub-runner
Direct hot runner ( as small as possible)
Gates and Runner are Very Important Component of the Part Design
2013 Celanese LCP-007 AM 10/13
30
Part Design
31
Part Design
Flex Modulus vs. Wall Thickness for Vectra E130i
30000
E130i
25000
MPa
20000
15000
10000
5000
0
0
2
3
Thickness, mm
32
Part Design
Mechanical properties are proportionally better in thinner wall
sections than thick ones.
Effect of wall thickness on rigidity (Vectra E130i Natural )
250
Tensile strength
200
150
100
50
0
4mm
3.2mm
1.6mm
0.8mm
0.7mm
0.6mm
33
Easy flowing
Fills long, thin-walled moldings
Output rate
Fast cycles
Dimensional requirements
Very low mold shrinkage
34
Thank you.
Questions?
For Additional Information Contact:
Cory Pierson, Field Technical Service
Cory.pierson@ticona.com
Edson Ito, Vectra LCP Technical Marketing
Edson.ito@ticona.com
2013 Celanese LCP-007 AM 10/13
Contact Information
Disclaimer
This publication was printed on 1 October, 2013 based on
Celaneses present state of knowledge, and Celanese
undertakes no obligation to update it. Because conditions of
product use are outside Celaneses control, Celanese makes
no warranties, express or implied, and assumes no liability in
connection with any use of this information. Nothing herein is
intended as a license to operate under or a recommendation
to infringe any patents.
Copyright 2013 Celanese or its affiliates.
All rights reserved.
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t: +1-800-833-4882 t: +1-859-372-3244
Customer Service
t: +1-800-526-4960 t: +1-859-372-3214
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e: info-engineeredmaterials-asia@celanese.com
36
37
12. Does the part have a snap fit? Glass filled materials will require more force to close
the snap fit, but will deflect less.
13. Will the part be subjected to impact? If so, radius the corners.
14. Is surface appearance important? If so, beware of weld lines, parting line, ejector
location, and gate vestige.
15. What color is required for the part? Is a specific match required or will the part be
color coded? Some glass or mineral filled materials do not color as well as unfilled
materials.
16. Will the part be painted? Is a primer required? Will the part go through a high
temperature paint oven?
17. Is weathering or UV exposure a factor?
18. What are the required tolerances? Can they be relaxed to make molding more
economical?
19. What is the expected weight of the part? Will it be too light (or too heavy)?
20. Is wear resistance required?
21. Does the part need to be sterilized? With what methods (chemical, steam, radiation)?
38
22. Will the part be insert molded or have a metal piece press fit in the plastic part?
Both methods result in continuous stress in the part.
23. Is there a living hinge designed in the part? Be careful with living hinges designed
for crystalline materials such as acetal.
24. What loading and resulting stress will the part see? And, at what temperature and
environment?
25. Will the part be loaded continuously or intermittently? Will permanent deformation
or creep be an issue?
26. What deflections are acceptable?
27. Is the part moldable? Are there undercuts? Are there sections that are too thick
or thin?
28. Will the part be machined?
29. What is the worst possible situation the part will be in? (For example, the part
may be outside for an extended period of time and intermittently put in water, or
the part may see a constant high load while submerged in gasoline at 150F.)
Parts should be tested in the worst case environment.
39