Molding Guide

Zenite

liquid crystal polymer resins

6000 and 7000 Series High Temperature LCP Resins

Melt

Shear Stress

Solid State Outstanding Properties Mechanical Chemical Dimensional Thermal Processing Electrical

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Zenite LCP Resins

Molding Guide

Table of Contents
Chapter 1General Information . . . . . . . . . . . . . . . . . . . . Resin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compositions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Melt Flow Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2Molding Equipment . . . . . . . . . . . . . . . . . . . . . Machine Melt Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nonreturn Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamping Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3Handling of Molding Resin . . . . . . . . . . . . . . . Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4Machine Operating Conditions . . . . . . . . . . . . Molding Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Melt Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mold Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pack Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw Forward Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw Speed and Back Pressure . . . . . . . . . . . . . . . . . . . . . Screw Decompression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycle Interruptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 2 2 2 2 3 3 4 4 4 5 5 6 7 7 7 7 7 8 9 9 10 10 10 10 10 11 11

Table of Contents

(continued)

Chapter 5Mold Design . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mold Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximizing Physical Properties . . . . . . . . . . . . . . . . . . . Sprues and Runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gate Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercuts and Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mold Shrinkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 7Operating Precautions . . . . . . . . . . . . . . . . . . . Thermal Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Off-Gases and Particulates . . . . . . . . . . . . . . . . . . . . . . . . Handling of Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 12 12 12 12 13 13 13 13 14 14 18 18 19 19 19

Chapter 6Troubleshooting Guide . . . . . . . . . . . . . . . . . . 16

Chapter 1 General Information

Resin Description
Zenite is the DuPont trademark for its liquid crystal polymer (LCP) resins. Zenite 6000 and 7000 series LCP resins are wholly aromatic polyester resins, and are easily melt processed. The materials feature excellent toughness, dimensional stability, and creep resistanceeven at very high temperatures. In the molten state, the polymers rod-like molecules are somewhat aligned. With high processing shear stresses, the molecular alignment is further enhanced. This, in turn, contributes to anisotropic propertiesincluding superior physical properties over a wide temperature range, low thermal expansion, and low mold shrinkage especially in the flow direction. The commercial grades are glass- or mineral-filled. These grades of Zenite LCP resins are ideal for a wide range of applications in the automotive, electrical/electronic, and industrial markets.

Melt Flow Characteristics

Zenite LCP resins have excellent melt flow characteristics. Filling of long, thin channels is possible due to the low melt viscosities at the recommended melt temperatures. Figure 1 shows the melt viscosities are about the same as nylon 66 and high density polyethylene and less than half of most other engineering plastics.
Figure 1. Melt Viscosity versus Melt Temperature at 1000 sec1 Shear Rate

Melt Temperature, F
300 500 390 480
Polyester Elastomer Acetal Homopolymer 30% GR PET
Zenite 7130

570

660

750

300

Melt Viscosity, Pas

200

Compositions
6130 30% glass-reinforced, 256C (493F) heat deflection temperature (HDT) 6330 30% mineral-reinforced, 235C (455F) HDT, more isotropic dimensional properties 7130 30% glass-reinforced, 295C (563F) HDT 7130HT 30% glass-reinforced, 300C (572F) HDT

100

HDPE Nylon 66

50
Zenite 6130

30 20 150

200

250

300

350

400

Melt Temperature, C

Chapter 2 Molding Equipment

Zenite LCP resins can be molded in all standard screw injection molding machines. General-purpose screws are usually adequate. Zenite LCP resins, like other glass-reinforced resins, can cause wear in certain areas of the barrel, screw, and mold. The materials of construction that are recommended below are based on vast experience with other DuPont glass-reinforced resins that are molded continuously or for significant lengths of time. If Zenite LCP resins are to be run in such volumes, these steps should be considered. and high output rates. In all cases, the temperature of the nozzle should be independently and precisely controlled. High wattage ceramic heater bands are required in order for all zones to reach and be controlled at the high temperature settings of 350380C (660715F). A means of controlling the temperature at the barrel feed throat must also be incorporated. Cooling water to the feed throat should be controlled by a needle valve. A dial thermometer can be used to measure the throat temperature. Barrel length should be at least 20 times the diameter for uniform melt temperature at high outputs.

Machine Melt Capacity

The plastifying capacity of any screw injection molding machine primarily depends on the screw diameter and design.

Shot Size Shot size is equal to the volume of molten resin injected by the screw during the cycle. The melt densities of Zenite LCP resins are approximately 45% higher than the melt density for polystyrene (the standard used for specifying molding machines) at normal temperatures and pressures. For the best molding (reasonable residence time), the shot size should utilize between 30 and 70% of the maximum stroke of the screw. Screw Recovery Rate Screw retraction (recovery) is influenced by cycle time, screw design, screw speed, back pressure, cylinder temperature profile, shot size, and, as with all glass-reinforced resins, screw and barrel wear. For guidelines to screw speed, see Table 4 (in Screw Speed under Chapter 4: Machine Operating Conditions).

Wear Bimetallic barrel liners, e.g., Xaloy1 100/101 or 800 types (or equivalent), have shown outstanding resistance to wear by glass fibers.

Screw Design
General The general-purpose gradual compression screws that are installed (OEM) in molding machines are usually suitable for molding Zenite LCP resins. Successful moldings have been accomplished with screw compression ratios ranging from 2.0 to 3.5. For uniform melt temperature control, length/ diameter ratios of 18/1 to 20/1 are recommended. Wear Abrasive wear by glass on injection screws occurs primarily on the lands and edges of screw flights. In time, the root diameter will wear somewhat in the transition and metering zones. Use heat-treated and stress-relieved alloy steel with a hard surface. For best results, the screw should be made of CPM-9V2 tool steel and the flight tips be hard surfaced with Colmonoy No. 56.3
1 2

Barrel
General Three-zone heating control of the barrel (corresponding to the screws three functional zones) should be provided for precise temperature control

Xaloy, Inc., Pulaski, VA Crucible Co., Camillus, NY 3 Colmonoy Corp., Madison Heights, MI

Nonreturn Valve
General Hardened sliding-type ring check (nonreturn) valves should be used for processing Zenite LCP resinseither the more common ring check type or a ball check valve may be used. In either case, the flow passages must be streamlined and nonrestricted to prevent problems associated with hold-up spots. See Figure 2 for a good generalized design of a nonreturn valve.
Figure 2. Nonreturn Valve
RING

use of a reverse taper bore nozzle (see Figure 4) is recommended. The nozzle temperature should be independently and precisely controlled. The heater band and thermocouple should be placed as far forward as practical for good temperature control. High wattage ceramic heater bands should be used to maintain a temperature up to 380C (715F). Although not recommended, positive shut-off nozzles can be used when proper temperature control is provided. Again, streamlining is important and the risk of hold-up spots can be a concern.
Figure 3. Free-flow Nozzles
THERMOCOUPLE WELL

RING SEAT

MELT FLOW HEATER BANDS

MELT FLOW

Wear Ring check valves (nonreturn valves), especially when not hardened, undergo rapid and appreciable wear when used with glass-reinforced resins. Even when properly hard-surfaced, these valves should be considered expendable after 34 months of such use. Prior to that, worn seats and ring sleeves should be reground or replaced as it is important to maintain a pad (cushion) during melt injection. Typical materials of construction are H-13 tool steel or CPM 9V for highest wear resistance. In either case, nitriding can be useful for extending the life of check rings. The seat is usually hardened higher than the sleeve; e.g., seat Rc62 and sleeve Rc55 are typical. Experience has shown that when the nonreturn valve fails to function correctly, additional screw wear occurs and as the performance (wear) of the check valve worsens, so does the condition of the screw.

Figure 4. Nozzle (with Reverse Taper) for Molding Zenite LCP Resins

0.25 mm (0.01 in) RADIUS 3.2 mm (1/8 in) or 4.8 mm (3/16 in) DIAMETER 4 25.4 mm (1 in) 50.8 mm (2 in) DIAMETER AND ANGLE TO SUIT

HEATER BAND

NOT TO SCALE

Nozzle
Conventional free-flow type nozzles (see Figure 3) can be used, especially with small orifice diameters. For larger diameters, or if drooling is a problem, the

Hydraulic System
When molding Zenite LCP resins, it is important to be able to inject the resin into the mold at a rapid and controlled rate. Machines with shot capacities of 570 g (20 oz) or less should have hydraulic pumping capacities that allow the rated shot capacity to be injected into the mold in 2 sec or less. Many LCP applications are small, thin-walled parts requiring a small machine capable of injecting in the 0.30.5 sec range. The ability to control the rate of injection is just as important as the ability to fill rapidly. For this reason, it is desirable to have pressure- and temperature-compensated flow control valves installed in the hydraulic system.

Injection Pressure
Although rarely required, the injection system should be capable of injecting Zenite LCP resins at melt pressures up to 1,380 bar (20,000 psi). However, lower pressures are recommended to avoid overpacking. Common injection pressures are in the 275550 bar (4,0008,000 psi) range. Accurate and reproducible control of the injection pressure is essential for maintaining tolerance of molded dimensions and other quality characteristics.

Clamping Capacity
Typical applications feature hard-to-fill parts and precise tolerance control. Molds should be designed and machines selected so that the clamping force is 550690 bar (45 tons/in2).

Chapter 3 Handling of Molding Resin

Drying
Although Zenite LCP resins do not absorb high amounts of moisture, levels less than 0.010% are recommended for optimum properties. The virgin resin is supplied somewhat above this level in a moisture-resistant package. Therefore, any resin (virgin or regrind) must be dried before processing to avoid any chance of hydrolytic degradation. If degradation should occur because of excessive moisture, there will be no evidence (such as splay) on the surface of the parts. Figure 5 shows moisture pickup after one year immersion in water. The moisture pick-up rate is quite slow. Even to reach the 0.010% processing maximum requires two days. Conversely, drying of the resin is accomplished in short time periods. Figure 6 shows such drying data at three temperatures. Table 1 contains recommendations at these temperatures for resin from the bag and for resin or regrind of unknown moisture history.
Table 1 Recommended Drying Times, hours Zenite LCP Resins
Drying Temperature 149 C (300 F) Resin from Bag Resin/Regrind of Unknown Moisture 1.0 2.5 135 C (275 F) 1.5 3.0 121 C (250 F) 2.5 4.0 Moisture, %
0.020

Figure 5.

Water Absorption of Zenite 6130 Total Immersion at 23C (73F)

0.08

0.06

Moisture, %

0.04

0.02

0 0 ASTM D570 10 20 30 40 50 60

Time, weeks

Figure 6.

Drying Data for Zenite 6130 in a Dehumidified Hopper Dryer

0.030

0.025 121C (250F)

0.015 135C (275F) 0.010 145C 0.005 (300F) Maximum Recommended Level

Dry in a dehumidified oven or hopper drier at the recommended time and temperature found in Table 1. Longer periods (such as overnight) at these temperatures can be used without affecting the resins moldability or properties. If the resins are to remain in ovens for longer lengths of time, it is good practice to either lower the heat to less than 65C (150F) or to remove and store the resin in clean, moistureresistant containers. The dryer air flow rate should be 3.03.7 m3/hr per kg/hr (0.81.0 CFM per lb/hr) of resin processed.
5

0 0 1 2 3 4

Time, hours

 Maintain the dew point of the inlet air at 18C (0F) or lower. If predried in a remote dehumidified oven or hopper, the molding machine must also be equipped with a dehumidified hopper drier in order to maintain the desired moisture level. The temperature and dew point should be the same as above. It is always a good practice to sample and run a moisture analysis prior to starting up production as well as during the run at a frequency consistent with normal quality control procedures to ensure that the level is <0.01%.

determining a maximum regrind percentage are many, e.g., UL and automotive requirements, product design requirements, drying, fines, and regrind quality. We have demonstrated that good property retention is possible at 100% regrind levels. The UL yellow card listing for HX6130 allows up to 50% regrind. However, customer testing around the specific end-use requirements is the most important tool for final selection of maximum regrind percentage. Conventional plastic granulators are used for grinding Zenite LCP resin grades. The blades should be sharp and set for close clearance and the screen size should be as large as practical for feeding the particular machine. However, due to the fibular nature of all LCPs, a high degree of fines and ragged cut can occur. To optimize the cut, sprues and runners should be fed to the grinder immediately out of the mold while still hot. The fines can be further separated by a post-screening operation. Another option is to repelletize the regrind through an extruder. This, of course, adds an additional heat history to the resin. Caution: Do not mix other LCP resin regrind with Zenite LCP resin regrind. Severe degradation of other LCP resins can occur when molded at Zenite LCP resin melt temperatures.

Regrind
Zenite LCP resins have excellent thermal stability when using recommended molding conditions. This results in a remarkable retention of properties when using regrind. Studies with Zenite 6130 using 25, 50, and 100% regrind have been run for a total of 68 passes (virgin resin plus 57 regrind). Table 2 exhibits the excellent retention (>90%) of its physical properties. In addition, measurements of shrinkage on 127 12.7 1.59 mm (5 0.5 0.0625 in) bars showed only a 0.03% shrinkage increase in the flow direction and an unmeasurable change in the transverse direction after five passes versus the virgin resin pass. The considerations around

Table 2 Zenite 6130 Regrind Studies

Property Tensile Strength, 23C (73F) Method ASTM D638 Regrind Level, % 100 50 25 100 50 25 100 50 25 100 100 100 50 25 Retention, % (6th Pass) 96 98 97 100 100 90 100 100 100 92 94 99 100 100 100 Retention, % (8th Pass) 96

Elongation at Break, 23C (73F)

D638

95

Tensile Modulus, 23C (73F)

D638

100

Flexural Strength, 23C (73F) Flexural Modulus, 23C (73F) Heat Deflection Temperature at 1.8 MPa (264 psi) Izod Impact, 23C (73F)

D790 D790 D648 D256

Chapter 4 Machine Operating Conditions

Molding Machine
As is good practice with all resins, the molding machine selected should have a shot weight that utilizes 3070% of the maximum stroke. Zenite LCP resins exhibit excellent melt stability. These resins have broad melting points versus other engineering plastics. The minimum melt processing temperature is just greater than the broad melting point range as seen in Figure 7 and listed in Table 3. Although the resins can physically be molded below the minimum in the preferred melt temperature ranges in Table 3, poor physical propertiesespecially brittle partscould result. Therefore, the resins should not be molded below the minimum values listed in Table 3.
Figure 7. DSC Curves of Zenite LCP Resins

Melt Temperature
As with all resins, achieving and controlling the desired melt (or stock) temperature is essential to a successful molding. The melt temperature is a result of cylinder and screw design, heater design, screw back pressure, screw rotation rate (rpm), shot size, and overall cycle time. Table 3 provides typical cylinder settings which can vary widely depending on the particular equipment.
Table 3 Typical Processing Conditions for Molding Zenite LCP Resins
Typical Cylinder Temperatures Zenite Rear Center Resin Series C ( F) C ( F) 6130 6150 6330 7130 Front C ( F) Preferred Melt Temperature Range C ( F)

0.35 0.36 6130

350C Minimum Processing Temperature

Heat Flow, W/g

0.37

0.17 0.18 0.19 HEAT-UP 0.20 260 280 300 320 340 360 380 400 7130
363C Minimum Processing Temperature

340 (645) 343 (650) 346 (655) 349360 (660680) 352 (665) 354 (670) 357 (675) 363371 (685700)

Temperature, C

7130HT 354 (670) 357 (675) 360 (680) 366377 (690710)

Because it is not possible to accurately predict the combined effect of all the variables, the actual melt temperature should be measured after the machine operation has reached equilibrium. This is best done by taking air shots into an insulated container and measuring with a fast-response (needle probe) pyrometer. In order to adequately measure the temperature, three or more air shots may be required. In general, settings run lower than desired melt temperature due to heat provided by the screw working with the resin. In order for all zones to reach and be controlled at the desired settings, high wattage ceramic heater bands are strongly recommended and are a must for the 7000 series.
7

Nozzle Temperature
The nozzle must not affect the temperature of the melt. Ideally, the temperature of the melt entering and leaving the nozzle should be the same. The nozzle temperature setting will depend largely on the design of the nozzle, the heater band placement, the temperature of the mold in contact with the nozzle, and the overall cycle. The nozzle temperature setting is usually similar to the front zone setting.

Mold Temperature
Zenite LCP resins mold well over a wide range of mold temperatures. Mold surface temperatures over a range of 40150C (100300F) have been used. The most common range is 65110C (150230F).

Mold Shrinkage, %

High temperatures should be used for thin, hard-tofill parts. (Good safety practices require using hightemperature rated hoses for hot water or hot oil heaters.) Low temperatures are recommended with complex parts experiencing sticking problems. Since mold surface temperature is a product of many variables (not just the cooling fluid), it must be measured at start-up (once on cycle) and after any major process change. Unlike many other materials, the effect of mold temperature on shrinkage and post-molding shrinkage is quite small. The effect on transverse flow and thickness are essentially unmeasurable. On highly aligned flow parts, there is a measurable effect in the flow direction as the molecular alignment is further ordered at the higher mold temperatures or when annealed at very high temperatures. In each case, this alignment results in part growth, once out of the cavity, such that it can be larger than the cavity dimension. This is especially true for thinwall section parts. This is shown as a negative shrinkage in Table 5 (see Mold Shrinkage under Chapter 5: Mold Design) as well as in Figure 8. This graph shows that over a 100C (180F) mold temperature range, a small increase of 0.15% (1.5 mil/in) is seen on 3.2 mm (0.125 in) parts. Similarly, Figure 9 shows a small part growth on 0.79 mm (0.032 in) parts after exposure to 260C (500F) temperature for 30 min. This growth decreased from 0.2% (2.0 mil/in) to 0.12% (1.2 mil/in) over the same mold temperature range.

Figure 8. Mold Shrinkage versus Mold Temperature 3.18 mm (0.125 in) ThicknessFlow Direction
Mold Temperature, F
105 0.15 140 175 210 245 280

0.1
6130 7130

0.05

0.05

0.1 0.15 40 60 80 100 120 140

Mold Temperature, C

Specimen: 216 mm (8.5 in) x 12.7 mm (0.5 in) Negative mold shrinkage means part growth out of mold to dimensions greater than the cavity dimensions.

Figure 9. Dimensional Growth in Flow DIrection with Annealing at 260C (500F) for 30 min Mold Temperature, F
0.25 105 140 175 210 245 280

Injection Pressure
Depending on the molding machine design, the injection pressure may or may not be an independent setting. The actual injection pressure will be influenced by both the injection rate and the transfer (position, pressure, or time) settings. Since these resins are quite fluid at the recommended high injection rates, relatively low injection pressures of 200400 bar (3,0006,000 psi) are usually the case. In the case of extremely hard-to-fill parts, pressures approaching maximum machine capability are sometimes required. Figure 10 is typical snake flow data that is somewhat indicative of melt flow lengths possible in molding at 0.51 mm (0.020 in) thickness. In almost all cases, start-up with a lowpressure setting is recommended.
Part Growth, %

0.2
6130

0.15

0.1

0.05

40

60

80

100

120

140

Mold Temperature, C Specimen: 0.79 mm (0.032 in) Thickness 127 mm (5.0 in) x 12.7 mm (0.5 in)

Figure 10. Flow versus Pressure 12.7 mm (0.500 in) Width

Figure 11. Melt Viscosity versus Shear Rate

Injection Pressure, kpsi

4 30 7 10 13 16 19 12

200

Zenite 7130 360C (680F) Melt Temp.

25

Melt Viscosity, Pas

Zenite 6130 355C (670F) Zenite 7130 365C (690F)

10

100
Zenite 6130 355C (670F) Melt Temp.

Flow Length, cm

Flow Length, in

20

50
Zenite 6130 370C (698F) Melt Temp.

15

30

10

20

5 200

400

600

800

1,000

1,200

2 1,400
10 500 1,000 2,000 3,000 5,000

Injection Pressure, bar Open-end snake flow mold. Actual flow lengths will be less in conventional molds.

Shear Rate, sec1

Injection Rate
Injection rate is also known as fill rate or speed. Depending on the machine design, it may be set in volume per unit time over a range of distance or time. Older machines may only utilize a high volume (booster) pump over a time setting. Injection rate is a key variable in the molding of Zenite LCP resins. Previously, Figure 1 showed the significant effect melt temperature had on melt viscosity. Likewise, Figure 11 depicts the high sensitivity of these resins to shear rate. Therefore, in order to capitalize on their low viscosity and high flow capabilities, very high fill rates are utilized over almost 100% of the stroke. Fill (or ram-inmotion) times of 0.31.0 sec are very common in small part volumes, such as electronic connectors and bobbins. Fast injection rates also contribute to the anisotropic properties, including high physical properties, low thermal expansion, and low mold shrinkage in the flow direction. When the fill rate is reduced, the viscosity is significantly increased such that the polymers flow can quickly stop and set up. Therefore a high injection rate for 9598% of the stroke followed by a low

(5075% less) rate for the very end of the stroke allows for filling long, thin sections without incurring flash problems. This assumes adequate venting has been provided to prevent part burning at the end of flow (see Vents in Chapter 5: Mold Design). Note: The viscosities for mold design programs are measured by a different procedure (see Chapter 5: Mold Design).

Pack Pressure
Pack pressure is usually about 80% that of injection pressure. The complexity of the part and its effect on ease of ejection will also determine the optimum pack pressure. For complex parts, it is recommended to start with low (e.g., 138 bar [2,000 psi]), pack pressure and then increase it in small increments. Because these resins set up very quickly, the gates will quickly freeze and pack time is quite short versus other thermoplastic resins. For thinwall section parts (e.g., 0.76 mm [0.030 in]), it can be less than a second. Due to the low shrinkage of Zenite LCP resins, it is possible to overpack and stick parts, especially in the area of the sprue. Therefore, pack pressures and times should be increased carefully.

Screw Forward Time

Screw forward time is the time interval between the start of screw forward motion (injection) and the start of screw retraction. The optimum screw forward time can be determined by molding and weighing a series of parts (not sprue and runners) at different screw forward times. In thick section parts (e.g., 3.18 mm [0.125 in] or more), this can be done by the traditional method of keeping the fill time constant by increasing the pack times (holding the overall cycle time constant) until the part reaches maximum weight. However, in thin section parts, pack time can be less than a second. Increasing the injection pressure to the maximum (short of flashing) is the preferred method. This is particularly effective for achieving maximum weld line strength together with using melt temperatures 10C (20F) above the maximum temperatures shown in Table 3.

Table 4 Maximum Screw rpm versus Screw Diameter

Screw Diameter, mm (in) 16 (0.63) 38 (1.5) 76 (3.0) Screw Speed, rpm 240 100 80

Screw Decompression
Screw decompression (or suck-back) should be a minimum and only used when necessary. Nozzle drooling can be controlled by drying the resin, proper nozzle temperature selection with good temperature control, and, if necessary, use of a reverse taper nozzle.

Start-Up
The cylinder and screw should be cleaned prior to start-up by using the method described under Purging. The recommended start-up procedure is: 1. Set the cylinder temperatures 30C (50F) below and the nozzle temperature 10C (20F) above the minimum processing temperature. Allow the heat to soak in for at least 20 min. Raise the cylinder temperatures to the desired operating temperatures. (Use Table 3 as a guide.) 2. Check to make sure that the nozzle is at set temperature and that it is open and contains no frozen material. 3. Jog the screw. If the screw will not rotate, allow a longer heat soak in time. 4. When the screw begins to rotate, open the hopper feed slot briefly and then close. As the material is being pumped forward by the screw, check the load on the screw motor. If it is excessive, increase cylinder temperatures. 5. Open the feed slide and increase back pressure to hold the screw in the forward position. Extrude melt and adjust operating conditions until the melt shows no indication of unmelted particles or degradation. A good melt will be smooth in appearance. If the melt is foamy, degradation is occurring. Once the melt is proper, release the back pressure.

Overall Cycle Time

The total cycle time is determined by the interaction of part thickness and geometry, molding machine and part design. All Zenite LCP resins have a low heat of fusion (~4 J/g versus 4050 J/g for many engineering plastics) which contributes to very fast cycle times. For example, thin wall connectors are routinely molded well under 10 sec. In general, overall cycle times are 3050% less than those of semicrystalline resins such as PBT, PET, and PPS.

Screw Speed and Back Pressure

For large shot sizes, screw speed should be selected so that the screw retraction time is approximately 90% of the available mold closed time. This is an effective way of minimizing hold-up time in front of the screw. However, in most thin-wall part molding, screw retraction time is often the limiting variable. In order to minimize glass fiber breakage, the screw speed should be slow and with small diameter screws, plasticizing capabilities are limited by clearances in the feed zone. Table 4 lists practical maximum screw rpms for several screw diameters that meet these various criteria. In addition, little or no back pressure should be used.

10

6. Take several air shots with the stroke size and cycle anticipated for the molding operation. Then check the melt temperature with a handheld pyrometer. Since Zenite LCP resins melt quickly and set up, three to five cycle checks may be needed to obtain an accurate melt temperature. Make any necessary adjustments in the cylinder temperatures to achieve the recommended melt temperature. 7. Bring the injection cylinder forward. Start molding on cycle at low injection pressure (except where short shots will interfere with part ejection) and then adjust operating conditions to produce quality parts.

followed by a low melt index (<1.0), high-density polyethylene (HDPE). Do not use a flame-retardant grade of PET which would seriously degrade at these temperatures. Also, do not use higher melt index polyethylenes which will not have enough viscosity at these temperatures to be an effective purge. Note: When the cylinder temperatures are above 290C (555F), the polyethylene must be continually purged because resin decomposition and ignition of the vapors might occur. Polystyrene should not be used as it will decompose at Zenite processing temperatures. The following purge procedures are recommended: From Other Resins to Zenite LCP Resins: 1. Retract the injection unit from the platen and increase the back pressure so that the screw is held in the forward position. 2. Run the screw at high rpm and pump out at its melt temperature as much of the resin as possible. Introduce the low melt index polyethylene purging material and feed until the extrudate comes out clean. 3. Empty the cylinder of polyethylene purge and raise temperature settings and proceed as outlined in the preceding Start-Up section. From Zenite LCP Resins to Other Resins: 1. Retract the injection unit from the platen and increase the back pressure so that the screw is held in the forward position. 2. Run the screw at high rpm and pump out at its melt temperature as much of the Zenite LCP resin as possible. Lower the temperature settings to 300C (570F) and feed Rynite 5554 until no further traces of Zenite LCP resins appear. Pump out as much of the Rynite 555 resin as possible. 3. Lower the cylinder temperature settings to 290C (555F) and feed the low melt index, polyethylene purging material until the extrudate comes out clean. Empty the cylinder of the polyethylene and proceed to start-up conditions for other resins or shut down.
4

Cycle Interruptions
Due to the excellent thermal stability of Zenite LCP resins, minor cycle delays up to 1015 min can usually be tolerated without purging and loss of material. If the delay is expected or reaches >15 min, empty the resin from the cylinder as some degradation will occur. No purge compound is necessary at this time. The cylinder temperatures should be lowered to 205230C (400450F). Upon resumption of the run, raise the temperatures and reintroduce the Zenite LCP resin per the start-up procedures. For anticipated delays greater than an hour, the resin must be purged sequentially with Rynite 545 or 555 polyester resin, followed by a low melt index polyethylene as described in the procedure for purging from Zenite LCP resins to other resins.

Purging
Purging is essential before and after molding Zenite LCP resins because many plastics (including other lower melting point LCPs) degrade at the Zenite LCP resins melt processing temperatures. Therefore, contamination with other resins (including other LCP resins) may cause molding difficulties or resin decomposition. Refer to Thermal Effects in Chapter 7: Operating Precautions for information on proper handling of the purge and provisions for local exhaust ventilation at the nozzle during purging and processing of Zenite LCP resins. The best purging is accomplished by using a high glass-reinforced PET such as Rynite 545 or 555,

If no high glass-reinforced PET is available, shut down and pull the screw for mechanical cleaning. Heat the barrel back up to processing temperature and clean with wire brush.

11

Chapter 5 Mold Design

General
Zenite LCP resins have been molded in a variety of molds. Many of the general construction rules followed for other engineering resins are applied when designing molds for Zenite LCP resins. This includes designing the tool to allow for uniform heating and cooling. Frequently, the construction of prototype molds is encouraged. There are also significant differences from other engineering resins. These include the low mold shrinkage, high processing temperatures and injection rates, fast set-up time and, most of all, the anisotropic nature of these resins. These offer unique opportunities in designing the mold. Most of these are addressed in the following comments. For further information, consult with your DuPont Zenite marketing/technical representative. Note: Parameters for Mold-Flow5 and C-Flow6 are available on request.

Maximizing Physical Properties

The anisotropic nature of Zenite LCP resins include shrinkage, thermal expansion coefficient, and basic mechanical properties. Therefore, in order to maximize part strength, the mold design should take into consideration the flow directions of one or more melt fronts so that no weld lines are formed in areas subject to high stress in use. This will include the selection of gate location, size and number, and vent location and size, together with the part design itself.

Sprues and Runners

Due to the high flow characteristics of Zenite LCP resins in high shear circumstances, sprue and runner sizes can be smaller than many other resins. This, of course, will depend on the overall flow length and wall thickness of the part. Single parting line runners of 38 mm (1.5 in) in length are often as thin as 1.6 mm (0.062 in) in thickness. Sprues should always be as short as possible with diameter at the primary runner being 1.0 to 1.25 times its thickness. Runners are progressively smaller so that the runner thickness at the gate is 1.25 times the maximum part thickness. It, of course, is best to minimize the overall runner length to ensure proper fill and packout of thin-wall, long flow-length parts. The best approach is to start with small runners and sprues and increase in size as necessary. Hot sprue bushings are frequently used with Zenite LCP resins and should be considered. Full round runners are preferred and normally used. Trapezoidal runners are sometimes used for greater ease of machining. The slope of the sides should be 5 per side, while the depth should be determined by the diameter of an inscribed circle. The layout of runners should be balanced with a generous radius at each branching for smooth and uniform melt flow.

Mold Materials
Zenite LCP resins are not corrosive to molds. However, glass, mineral, and other fillers may be abrasive and tool steels for cavities, cores, runner systems, and sprue bushings should be selected and hardened as with other filled engineering polymer resins. Also, as a result of the fast injection rates used in processing Zenite LCP resins, gates are subject to considerable heat buildup and loss of hardness. The use of replaceable gate block-inserts is recommended. They should be checked regularly and replaced as needed.
5

Moldflow Pty. Ltd., Melbourne, Australia and Moldflow, Inc., Shelton, CT 6 AC Technology, Ithaca, NY

12

Gate Location
The anisotropic nature of Zenite LCP resins is a product of both molecular and filler orientation during the filling of the mold. This orientation is influenced by both the direction of flow and the flow rate. Both are important to the physical properties in any given area. Gates should be located to give a uniform and uninterrupted flow. Weld lines are relatively weak versus other plastics, which is typical for all liquid crystal polymers. Whenever possible, multiple gating should not be used. The excellent flow characteristics of Zenite LCP resins usually only require a single gate. When it is impossible to avoid weld lines in a part, they should occur in areas that will not receive high mechanical stresses in use. At the same time, it is desirable to position the gate so that venting is simple and adequate (see Vents in this chapter). Avoid butt weld lines where two flow fronts hit head-on and stop. A melding of two flow fronts can eventually mix and become one. To further improve strength of weld lines, vents (and in many cases overflow tabs) should be positioned at weld line areas. In addition, melt temperatures should be raised up to 10C (20F) above the maximum temperatures shown in Table 3.

gate separation and part ejection. They should have a minimum diameter of 0.5 mm (0.020 in) and only be used with a short land length. Tunnel gates should also be located in the ejector side of the mold and designed to minimize part deflection during the ejection. It is best to position ejector pins below the tunnel gates. Rectangular gates are sometimes used since thickness (which affects gate freeze time) and width (thus volume which controls the flow rate) can be controlled independently. Gate thickness is usually 50% or less part wall thickness and gate width is 1.5 to 2 times the gate thickness. Often, a wide fan gate (up to full part width) is used on flat parts for control of orientation and optimum filling. Circular or conical parts should be center gated with a sprue gate or diaphragm gate, respectively. This will allow uniform flow fronts without weld lines.

Vents
Molds must be adequately vented in order to prevent localized burning of the parts, damage to the mold, poor weld line strength, and to allow easier filling of the cavity. Cavities should be vented at the parting line, at ejector pins, or by inserting a dummy knock-out pin into the cavity at the point where air is trapped. The vent depths range from 0.0080.025 mm (0.00030.0010 in) and as wide as practical. After a land length of about 0.75 mm (0.030 in) from the cavity, the vent depth should be enlarged to about 3.2 mm (0.125 in) and extended to the edge of the mold. In addition, runners should be vented at the sprue puller and parting line.

Gate Design
It is important to design gate dimensions so that polymer jetting into the cavity does not occur. The best design is to have gates located so that the melt directly impinges against the wall of the cavity or a core pinprovided that the core pin is registered in both mold halves. Parting line round gates are normally used on small parts and their diameter should also be about 50% of the wall thickness. Because of the unique Zenite LCP resin shear versus flow sensitivity (see Figure 11), gate thicknesses of 30% of wall thickness have been used (minimum dimension0.5 mm [0.020 in]). Too small of a gate thickness can result in gate freeze-off or fill problems. Tunnel gates are frequently used for ease of

Undercuts and Taper

Because of the high modulus and relatively low elongation of all LCPs, undercuts should be avoided. A taper of 0.20.5 on ribs, bosses, sides, and sprues is generally satisfactory. However, an additional 0.51.5 may be required for complex parts, parts with deep drafts, or for tools that do not have polished surfaces.

13

Mold Shrinkage
The mold shrinkage of Zenite LCP resins depends on the orientation of the molecules and fillers, part thickness and design, and processing conditions. Shrinkages listed in Table 5 are intended as a guide, using a typical mold temperature of 93C (200F), for estimating out-of-mold dimensions as a function of part thickness. Negative shrinkages (i.e., growth) can occur in the flow direction in thin wall sections. This means in these cases the part dimensions can be larger than the cavity dimensions. The effects of mold temperature and high use temperature on shrinkage have been previously discussed in the Mold Temperature section of Chapter 4: Machine Operating Conditions. Also refer to Figures 8 and 9. The use of regrind has little effect on mold shrinkage (see Chapter 3:
Table 5 Effect of Part Thickness on Mold Shrinkage, % Mold Temperature: 93C (200F)
Thickness mm (in) 0.81 (0.031) 1.62 (0.062) 3.2 (0.125)
1 2

Handling of Molding Resin).

Tolerances
Tolerances for parts molded of Zenite LCP resins vary according to the complexity and wall thickness of the design. Predicting dimensional uniformity can be difficult as it will depend to a large degree on the parts glass fiber and molecular orientation. The tolerances in Table 6 (based on the SPI format) are for 3.18 mm (0.125 in) wall section. They do not represent hard and fast rules applicable to all conditions, but rather an estimate based on experience. With the small wall sections often found in Zenite LCP resin moldings, the fine tolerance band often can be reduced by at least 50% in many cases. The ability to maintain minimum tolerances is dependent on part design, the number of cavities, mold design, the injection molding system used,

Zenite 6130 Flow 0.07 0.07 0.1

Zenite 7130

Transverse Flow Transverse 0.5 0.8 0.7 0.1 0.0 0.9 0.8

Disc: Edge-gated 102 mm (4 in) diameter Plaque: End-gated 76 127 mm (3 5 in)

14

Table 6 A Guide to Tolerances of Zenite LCP Resins

Note: The Commercial values shown below represent common production tolerances at the most economical level (see Note #2). The Fine values represent closer tolerances that can be held but at a greater cost. Drawing Code A = Diameter (see Note #1) B = Depth (see Note #3) C = Height (see Note #3) Dimensions mm (in) 0 (0.000) 25 (1.000) 50 (2.000) 75 (3.000) 100 (4.000) 125 (5.000) 150 (6.000) 0
FINE COMMERCIAL

Plus or Minus in Thousandths of an Inch 1 2 3 4 5 6 7 8 9 10 11 12 13

0.3 0.1 0.2 Plus or Minus in Millimeters

150 (6.000) to 300 (12.000) for each additional mm (inch) add (mm) [inches] D = Bottom Wall (see Note #3) E = Side Wall (see Note #4) 0 to 3 (0.000 to 0.125) F = Hole Size Diameter (see Note #1) 3 to 6 (0.125 to 0.250) 6 to 13 (0.250 to 0.500) 13 and Over (0.500 and Over) G = Hole Size Depth (see Note #5) Draft Allowance per Side (see Note #5) 0 to 6 (0.000 to 0.250) 6 to 13 (0.250 to 0.500) 13 to 25 (0.500 to 1.000)

Comm. 0.08 (0.003) 0.10 (0.004) 0.13 (0.005) 0.05 (0.002) 0.08 (0.003) 0.08 (0.003) 0.13 (0.005) 0.10 (0.004) 0.10 (0.004) 0.13 (0.005)

Fine 0.05 (0.002) 0.08 (0.003) 0.08 (0.003) 0.03 (0.001) 0.05 (0.002) 0.05 (0.002) 0.08 (0.003) 0.05 (0.002) 0.08 (0.003) 0.10 (0.004)

1.52.0

0.20.5

Reference Notes
1. These tolerances do not include allowance for annealing characteristics of material. 2. Tolerances based on 3.0 mm (0.125 in) wall section. 3. Parting line must be taken into consideration. 4. Part design should maintain a wall thickness as nearly constant as possible. Complete uniformity in this dimension is impossible to achieve. 5. Care must be taken that the ratio of the depth of a cored hole to its diameter does not reach a point that will result in excessive pin damage.
P/L G B F C A E

15

Flash

Sinks

Drooling

Warpage 4 4 4 Increase Injection Pressure Decrease Injection Pressure Increase Pack/Hold Pressure Decrease Pack/Hold Pressure 1 Increase Clamp Pressure 2 Increase Injection Rate Decrease Injection Rate 3 3 Increase Screw Forward Time Decrease Screw Forward Time 1 1 2 3 2 Increase Melt Temperature 4 Decrease Melt Temperature Increase Mold Temperature Decrease Mold Temperature 1 Decrease Nozzle Temperature Lower Center Zone Temperature Increase Cylinder Temperatures Increase Cycle Time 3 3 7 Decrease Cycle Time 1 1 1 Check Pad Size (Cushion) Check Screw Retraction 6 Use Melt Decompression Check for Resin Contamination 2 3 Ensure Resin Is Dry 5 2 2 5 5 4 3 2 4

Brittle Parts

Short Shots

Voids in Part

Sprue Sticking

Discoloration at End of Flow

Poor Weld Lines

Problem Areas

Parts Stick in Mold

Shot-to-Shot Variation in Part Size

Suggested Remedies

(In order of likely cause)

Screw Does Not Retract or Retracts Erratically

Chapter 6 Troubleshooting Guide Zenite LCP Resins

Quick (Operating Conditions) Changes

16 6 6 4 4 5 5 6 4 2

Longer (Equipment) Changes

Check Heater Band Temperatures 2 1

(In order of likely cause)

Repair Mold

Increase Size of Gate

Suggested Remedies

Problem Areas
Drooling Short Shots Sinks Voids in Part Flash Discoloration at End of Flow Poor Weld Lines Brittle Parts Parts Stick in Mold Sprue Sticking Shot-to-Shot Variation in Part Size Warpage Screw Does Not Retract or Retracts Erratically

5 7 8 5 5 7 6 6 3 1 5 6 6

3 2 6 1 5 7 6 3

17

Check Cylinder for Holdup Spots

Decrease Size of Gate (Shear)

Check Sprue for Undercuts

Use Reverse Taper Nozzle

Check Tool for Undercuts

Increase Draft of Mold

Change Gate Location

Enlarge Nozzle Orifice

Increase Sprue Taper

Enlarge Vents

Chapter 7 Operating Precautions

molding conditions, and the ability of the molder. Only by optimizing all of these variables can the tightest of tolerances be maintained. As with most thermoplastic resins, the molding of Zenite LCP resins is ordinarily a safe operation. Good practice dictates that consideration should be given to the following potential hazards: Thermal effects Off-gases and particulates Slipping hazards place. Reduce the injection pressure and jog the injection forward button a few times to minimize the possibility of trapped gas in the cylinder which will cause splattering of the polymer melt. If resin decomposition7 is suspected at any time, a purge shield should be positioned, the carriage (nozzle) retracted from the mold, and the screw rotated to empty the barrel. After the screw starts to rotate, the feed throat should be closed and then a suitable purge compound (high glass content PET) introduced. The temperature can then be gradually lowered and the machine shut down. See Purging under Chapter 4: Machine Operating Conditions for further details. If jogging the injection or screw rotation buttons does not produce melt flow, the nozzle may be plugged. In that case, shut off cylinder heats and follow your established safe practices. Always assume that gas at high pressure could be trapped behind the nozzle and that it could be released unexpectedly. A face shield and protective long sleeve gloves should be worn at such times. Before restarting, both the machine and material should be evaluated to determine the cause of the decomposition. In the event that molten polymer does contact the skin, cool the affected area immediately with cold water or an ice pack and get medical attention for thermal burn. Do not attempt to peel the polymer from the skin. Questions on this and other medical matters may be referred to 800-441-3637.

Thermal Effects
Skin contact with molten Zenite LCP resins can inflict severe burns. This could happen when gases generate pressure in the machine cylinder and violently eject molten polymer through the nozzle or hopper. To minimize the chance of an accident, the instructions given in this guide should be followed carefully. Potential hazards must be anticipated and either eliminated or guarded against by following established procedures, including the use of proper protective equipment and clothing. Be particularly alert during purging and whenever the resin is held in the machine at higher than usual temperatures or for longer than usual periods of time, as in a cycle interruption. Pay particular attention to Chapter 4: Machine Operating Conditions. When purging, be sure that the high volume (booster) pump is off and that a purge shield is in

Excessive gas escaping from the nozzle, severely discolored molten polymer, screw backing up beyond the rear limit switch, etc.

18

Because Zenite LCP resins are dried at high temperatures, contact with hot hoppers, ovens, or air hose lines could result in severe burns. Insulation of these components will reduce this possibility.

Handling of Resins
OSHA requires Material Safety Data Sheets (MSDSs) be provided by the material manufacturers to their customers. MSDSs include such information as hazardous components, health hazards, emergency and first aid procedures, disposal procedures, and storage information. DuPont supplies MSDS information to its customers with the initial order of a Zenite LCP resin and on the next order after an MSDS is revised. Zenite LCP resin MSDS will be furnished upon request from your DuPont representative.

Off-Gases and Particulates

During drying, purging, molding, and grinding operations, small amounts of gases and particulate matter are released. As a general principle, local exhaust ventilation is recommended during the processing of Zenite LCP resins as it is for all plastic resins. A ventilation rate of 4.68 m3 (75 ft3) air/min per kg/hr (lb/hr) of resin processed will keep the concentration of particulates (and gases) well below the OSHA8 limit of 15 mg/m 3 for nuisance dusts while being processed at the maximum recommended times and temperatures (molding, purging, and drying).

Slipping Hazards
Granules of Zenite LCP resins are a slipping hazard if spilled on the floor. Any spills should be swept up immediately.

29CFR1910.1000

19

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The data listed here fall within the normal range of properties but they should not be used to establish specification limits nor used alone as the basis of design. The DuPont Company assumes no obligations or liability for any advice furnished or for any results obtained with respect to this information. All such advice is given and accepted at the buyers risk. The disclosure of information herein is not a license to operate under, or a recommendation to infringe, any patent of DuPont or others. DuPont warrants that the use or sale of any material which is described herein and is offered for sale by DuPont does not infringe any patent covering the material itself, but does not warrant against infringement by reason of the use thereof in combination with other materials or in the operation of any process. CAUTION: Do not use in medical applications involving permanent implantation in the human body. For other medical applications, see DuPont Medical Caution Statement, H-50102.

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