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molding guide
AMODEL
®
polyphthalamide
molding guide
version 1.1
224284_SAP_cover.qxd 5/25/07 9:23 AM Page 2 Solvay Gives You
More Plastics with More Performance
than Any Other Company in the World
With over a dozen distinct families of high-performance
and ultra-performance plastics, Solvay Advanced Poly-
mers gives you more material choices to more perfectly
match your application needs. Plus, we give you more
global support for developing smart new designs.
We offer hundreds of product formulations including
modified and reinforced resins to help you tailor a solu-
tion to meet your precise requirements. From physical
properties and processability, to appearance and agency
approvals our plastics deliver more solutions.
Our family of amorphous sulfone polymers: Udel
®
polysulfone (PSU) Radel
®
R polyphenylsulfone (PPSU) Radel
®
A polyethersulfone (PES) Acudel
®
modified polyphenylsulfone
Our semi-crystalline aromatic polyamides: Amodel
®
polyphthalamide (PPA) Ixef
®
polyarylamide (PARA)
Additional semi-crystalline polymers: Primef
®
polyphenylene sulfide (PPS) Xydar
®
liquid crystal polymer (LCP)
Our Spire
®
family of ultra polymers: KetaSpire
®
polyetheretherketone (PEEK) AvaSpire
®
modified PEEK PrimoSpire
®
self-reinforced polyphenylene (SRP) EpiSpire high-temperature sulfone (HTS) Torlon
®
polyamide-imide (PAI)
Fluoropoly
mers
LCP
PARA
PPS, PPA
Specialty Polyamides
PBT, PET, PVDC
POM, PA 6, PA 6,6
TPO, TPV, PE UHMW
COC, PPC, PC
PUR, PPO
ABS, PMMA, PEX, XLPE Table of Contents
AMODEL Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Drying the Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drying Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drying Time and Temperature . . . . . . . . . . . . . . . . . . . . 3
Maintain Resin Dryness . . . . . . . . . . . . . . . . . . . . . . . . . 4
Consequences of Inadequate Moisture Content Control. . 4
Processing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Injection Molding Machine Considerations . . . . . . . . . . . 5
Mold Temperature Control . . . . . . . . . . . . . . . . . . . . . . . 5
Processing Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Starting Point Machine Settings . . . . . . . . . . . . . . . . . . . 7
Barrel Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Molding Cycle Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Polymer Injection or Mold Filling . . . . . . . . . . . . . . . . . 7
Packing and Holding. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mold Temperature and Control . . . . . . . . . . . . . . . . . . . . 8
Insert Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mold Releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Material Suitable for Regrinding . . . . . . . . . . . . . . . . . . . 9
Amount of Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Molding Process Effects . . . . . . . . . . . . . . . . . . . . . . . . 10
Regrind Usage Schemes. . . . . . . . . . . . . . . . . . . . . . . . 11
Continuous Regrind Addition. . . . . . . . . . . . . . . . . . . 11
Cascading Regrind Use. . . . . . . . . . . . . . . . . . . . . . . 11
Part Specifications and Qualification . . . . . . . . . . . . . . . . 11
Optimizing Regrind Use . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove Contamination . . . . . . . . . . . . . . . . . . . . . . 11
Classify by Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Blend Completely with Virgin Resin . . . . . . . . . . . . . 12
Use Constant Amounts . . . . . . . . . . . . . . . . . . . . . . . 12
Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Purging in Routine Circumstances . . . . . . . . . . . . . . . . 12
Cycle Interrupt Purge Procedure . . . . . . . . . . . . . . . . 13
Daily Shut-Down Procedure . . . . . . . . . . . . . . . . . . . 13
Changeover Procedure . . . . . . . . . . . . . . . . . . . . . . 13
Purging in Non-Routine Circumstances. . . . . . . . . . . . . 13
Loss of Electrical Power to Molding Machine . . . . . . 13
Loss of Barrel or Nozzle Heater Band . . . . . . . . . . . . 13
Loss of Thermocouple Control on a Heater Band . . . 13
Nozzle Obstruction . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Loss of Molding Machine Function . . . . . . . . . . . . . . 14
Mold Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tool Steels and Surface Treatments . . . . . . . . . . . . . . . 15
Mold Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Two-Plate Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Three-Plate Molds . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hot Runner Systems. . . . . . . . . . . . . . . . . . . . . . . . . 16
Balancing Cavity Layout . . . . . . . . . . . . . . . . . . . . . . 16
Thermal Management . . . . . . . . . . . . . . . . . . . . . . . . . 17
Runner Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sprue Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Edge Gates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Diaphragm Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tunnel or Submarine Gates . . . . . . . . . . . . . . . . . . . 18
Hot Runner Molds. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Molding Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Part Ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Draft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mold Polish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ejector Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Stripper Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Stationary Plate Ejectors. . . . . . . . . . . . . . . . . . . . . . 21
Collapsible Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mold Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 AMODEL Resins
AMODEL
®
polyphthalamide (PPA) is a family of semi-crys-
talline engineering polymers that bridges the cost-perfor-
mance gap between traditional engineering thermoplas-
tics such as polycarbonate, polyamides, polyesters, and
acetals and higher-cost specialty polymers such as
liquid crystal polymers, polyphenylene sulfide, and
polyetherimide.
AMODEL resin has excellent mechanical properties
strength, stiffness, fatigue and creep resistance over a
broad temperature range. Glass-reinforced grades pro-
vide higher stiffness, strength, and creep resistance at
elevated temperatures for structural applications.
Mineral-filled resins offer enhanced dimensional stability
and flatness. Some of these grades can be plated and
epoxy-coated. Impact-modified grades can provide sig-
nificantly improved toughness comparable to the
super-tough nylons but with much higher strength and
stiffness across a broad humidity and temperature range
Unreinforced grades of AMODEL resin are formulated for
general-purpose injection molding and extrusion applica-
tions that require high surface gloss, lubricity, low
warpage and toughness, along with a high level of
mechanical performance at elevated temperature. Gen-
eral characteristics of the AMODEL resin families are
shown in Table 1.
Injection Molding AMODEL Resins
1
Product Family
General Description
Glass-Reinforced
These resins cost-effectively maxi-
mize strength and stiffness proper-
ties and are typically used in
applications requiring structural in-
tegrity at elevated temperatures.
Mineral/Glass-Filled
These materials offer stiffness and
thermal performance approaching
glass-reinforced products with
better dimensional stability and
lower cost.
Flame-Retardant
These grades are specially formu-
lated for flame retardance, rated
94 V0 at 0.032 in. (0.8 mm), rated
94-5V at 0.062 in. (1.6 mm), and
are vapor phase and