General information on

applications, processing

and properties

DSM Engineering Plastics

Stanyl® PA46

Contents

Introduction 4

Automotve applications 7

Electrical and Electronicapplications 11

Consumer durables and otherapplications 17

Processing with Stanyl 18Typical shrinkage values 18Part dimensions 18Shrinkage of mouldings 18Warpage 19Conditioning of Stanyl components 20

Equipment 21

Material handling 25

Characteristics properties ofStanyl® PA46 30General 30Temperature Performance 31Short Term Heat Performance 31Long Term Heat Performance 33Heat ageing in air 34Flow 39Water absorption and hydrolysisresistance 41Electrical properties, flammability and UL classifications 43After-treatments 43

DSM EP Product portfolio 45

Typical data 47

Contact information 48

DSM

DSM is active worldwide in life scienceproducts, performance materials andindustrial chemicals. The group hasannual sales of close to EUR 6 billionand employs about 20,000 people atmore than 200 sites across the world.DSM ranks among the global leaders inmany of its fields. The company’sstrategic aim is to grow its sales (partlythrough acquisitions) to a level ofapprox. EUR 10 billion in 2005. By thattime at least 80% of sales should begenerated by specialties, i.e. advancedchemical and biotechnological productsfor the life science industry andperformance materials.

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DSM Engineering Plastics is aBusiness Group in the performancematerials cluster of DSM, with sales in2001 of EUR 603 million andapprox.1350 employees worldwide. It isone of the world’s leading players in thefield of engineering thermoplasticsoffering a broad portfolio of highperforming products.

DSM Engineering Plastics operates in allmajor markets of the world including theAmericas, Asia, and Europe. Within eachregion customers can count on ourinnovative research, development, andsupport facilities. Our in-house resourcesare backed by a corporate research anddevelopment center that is utilized increating new solutions for customerneeds. The advanced level of accountmanagement, in combination with oureffective global communication networksecures the support customers needwherever it is required.

With polymerization and compoundingfacilities for a range of polyamides,polyesters, polycarbonate and Ultra HighMolecular Weight PE and extrudableadhesive resins, we serve our globalcustomers base and assure a constant,reliable supply of products.

All our compounding facilities in theworld (in the Netherlands, Belgium, USA,Canada, China and India) are beingexpanded continuously to keep up withthe growing demand.

As a result of a constant productinnovation and creation process, DSMEngineering Plastics can offer a cohesiveportfolio of high performing engineeringplastics.

Established trade names are:Akulon® (PA6 and PA66)Akulon® UltraflowTM

(high flow Akulon PA6)Arnite® (PBT, PET)Arnitel® (TPE-E)Stamylan® UH (UHMWPE)Stanyl® PA46 (PA46)Stanyl® PA46 High FlowTM

(high flow PA46)Stapron® (PC-blends)Xantar® (PC)Xantar® C (PC/ABS-blends)Yparex® (extrudable adhesive resins)

Complemented in some regions byproducts as:Electrafil® (conductive products)Fiberfil® (reinforced polypropylene)Nylatron® (PA66 specialties)Plaslube® (lubricated products)

These materials all have their specificproperties, yet they share the same highquality, thanks to state-of-the-artproduction processes and qualitysystems, like Total Quality Management,ISO 9001 and QS 9000.It’s an approach to quality that can befound throughout the DSM organization:- in relations with industry partners,

working closely together in true co-makership, ready to meet anytechnical challenge

- in technical service and after sales,providing support to help customers,optimize their processes

- in logistics and delivery, shippingproducts anywhere in the world,quickly and reliably.

From product concept, throughprocessing, to final application DSMEngineering Plastics brings the portfolio,the skills and the global presence to helpits industrial partners create world-classproducts and solutions.

It’s surprising what we can dotogether!

Production sites

EuropeEmmen - Netherlands(polymerization and compounding)Geleen - Netherlands(polymerization)Genk - Belgium(compounding)Stade - Germany(polymerization)

North AmericaEvansville - Indiana(compounding)Augusta - Georgia(polymerization)Stoney Creek - Ontario Canada(compounding)

Asia PacificJiangsu - China(compounding)Pune - India(compounding)Tokyo - Japan(M/S joint venture and toll compounding)

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Properties PA6 PA66 StanylMelting point (°C) 225 265 295

Density (kg/m3) 1140 1140 1180

Crystallization rate- at 200 °C (min-1) 0.2 6 >15- at 230 °C 0 0.7 10

Table 1. Typical properties dependent on structure.

Grades Non-reinforced GF-reinforced % GFNon-flame retardant TW341 TW200F3 15(HB or V-2) TW363 TE200F6 30

TW200F6 30TW200F8 40TW241F10 50

Flame retardant TE350 TE250F6 30(V-0) TE250F8 40

46HF5040 40

Wear and friction TW371 TW271F6 30

Table 2. Most important grades of the Stanyl product portfolio.

Introduction

Stanyl® PA46 overview

Stanyl (polyamide 46) is DSM’s heatresistant polyamide. Stanyl is used indemanding applications in theautomotive and electrical and electronicsindustries, but it also meets many otherapplication requirements. It is analiphatic polyamide formed by thepolycondensation of 1,4-diaminobutaneand adipic acid. Although there aresimilarities between the molecularstructure of Stanyl (see Figure 1) andthat of PA66, the higher number ofamide groups per given chain length andthe more symmetrical chain structure ofStanyl result in the higher meltingtemperature of 295 °C, a highercrystallinity, and a faster rate ofcrystallization (see Table 1).

Stanyl’s crystallinity is approximately70%, compared with 50% for PA66.This results in a high heat distortiontemperature of 190 °C for unreinforcedStanyl and 290 °C for glass fibrereinforced Stanyl. These features giveStanyl a technical edge over otherengineering plastics like polyamide 6 and66, polyesters and semi-aromaticpolyamides (PPA’s) with regard to heatresistance, mechanical properties atelevated temperatures, wear and frictionbehaviour and, due an advantage incycle-time, improved processingeconomics.

Stanyl is produced and marketedexclusively by DSM and is availableworldwide. Compounding is carried outin Europe, the USA, Asia and Japan.Technical support in design, moulding,and material selection is provided by adedicated staff of specialists. Thissupport is provided locally and on aglobal basis.

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Front view of the complete Stanyl plant at the DSM site in Geleen.

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Figure 1.Differences in thestructure ofpolyamides.

Stanyl’s excellent properties (see Table 1and Figure 2) lead to importantadvantages for the customer such ascost reduction, longer lifetime, and highreliability. Stanyl bridges the gapbetween conventional engineeringplastics such as PA6, PA66, PBT andPET, and exotic materials such as LCP,PPS and PEEK.

Benefits for both moulders and endusers include:- resistance to high temperatures- 30% productivity increase of moulding

equipment- greater design freedom due to the

excellent mechanical properties andgood mould-flow behaviour

- economical, safe and convenientprocessing due to the use of water-heated moulds

- no post-treatment due to the absenceof flash

- no retooling necessary when switchingfrom PA6, PA66 or polyesters.

Stanyl® PA46 product range

Stanyl is offered in a wide variety ofgrades including unfilled (non-reinforced), as well as grades containingglass fibres, minerals, lubricants, impactmodifiers or flame retardants. A list of themost important grades can be found inTable 2.

Figure 2. Stanyl’sexcellent properties atelevated temperature(160 °C).

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Table 3a. Stanyl product coding.

T W 2 00 F 6T = granulate

W = standard heat stabilizerE = heat stabilizer for E&E applications

Indication of viscosity2 = low3 = medium4 = high

Indication of modification material00 = unmodified40’s = lubricated50’s = flame retardant60’s = impact modified70’s = low friction/wear

ReinforcementF = glass fibresK, M = mineralsS = glass spheres

Percentage reinforcement# x 5 = % reinforcement (e.g. 3 x 5 = 15% reinforcement)

46 HF 50 40Polymer type

High flow

Flame retardant

40% Glass fibres

Table 3b. Stanyl High Flow product coding.

A detailed overview of the Stanyl productcoding and nomenclature can be foundin Tables 3a and b.

ZIF PGA. Stanyl 46HF5040 is used for its extreme good flow and itsreduced warpage sensitivity.

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Stanyl withstands high loads andstresses at high temperatures andexposure to aggressive environments,and is therefore suitable for under-the-bonnet applications.Typical Stanyl applications are to befound in the engine and transmission,engine-management, air-inlet, brake, aircooling and electronic systems (seeTable 4).Many automotive fasteners have alsobeen produced in Stanyl, because of itsexcellent creep resistance, toughnessand good wear characteristics.

Engine

Engine applications are generally used invery demanding environments whereStanyl’s high stiffness at elevatedtemperatures, its high melting point (295°C), toughness, and excellent wearproperties provide outstandingperformance regardless of engine size orconfiguration. With trends in weight, costand noise reduction, Stanyl offersopportunities in all kinds of engines.

Metal replacement with Stanyl has beenespecially successful in parts integration,Noise Vibration Harshness (NVH) andcomponent wear and durabilityimprovement.

Successful and potential highperformance engine applications include:- air-intake manifolds- chain tensioners and guides - threaded oil filter housings- sensors- timing and starter gears - belt tensioner parts- gasket carriers- intercooler parts.

Automotive applications

General

Heat resistant plastics are increasinglyreplacing traditional engineering plasticsin automotive applications. The drivingforce behind this development is theneed to respond to three major industrytrends:- the growing use of new electronic

systems for improved safety, comfortand motor management.

- the demand for longer warrantyperiods and operating life time.

- the increase in under-the-bonnettemperatures caused by: • encapsulation of the engine for

acoustic-insulation and/or aestheticreasons

• introduction of turbo chargers andcatalytic converter systems, whichradiate considerable amounts ofheat

• size reduction of the enginecompartment due to more compactdesign.

Stanyl has proven to be an idealreplacement for metal for economicreasons.Stanyl offers excellent creep resistance,strength, stiffness and fatigue resistance,not only at ambient temperatures butespecially at high temperatures, while atthe same time providing the well-knownadvantages of plastics. These are freedom to develop complexdesigns and integrated functions, easierprocessing and limited finishingrequirements, weight and noisereduction, and corrosion resistance.Stanyl has been approved by all majorautomotive manufacturers.

Table 4. Typical automotive applications of Stanyl

Engine Chain tensioners, engine covers, oil filter parts

Transmission Clutch rings, shift forks, thrust washers, bearing cages,torsion damper parts, one way clutch cages

Air-inlet Emission control systems, air-inlet devices, enginemanagement parts, valves for exhaust gas control and pump housings for secondary air supply systems

Cooling lntercooler end-caps

Electrical components Alternator parts, sensors and switches, connectors,electromotor parts, ignition parts

Others Clips, fasteners, cable channels, tubing

Stanyl for automotive signalling lampsStanyl is applied in automotive lighting for signalling lamps. It is used for lamp bases and is selected for a combination of properties: high peak temperature, high heat resistance, high toughness and laser markability.See internet website www.lighting.philips.com/automotive for further information.

With guarantees exceeding 100.000 kmfor engines between tune-ups androadside service at the car companiesexpense, engine and power traincomponents must be lasting anddurable. Stanyl’s proven success makesit an ideal candidate for enginecomponent improvement.

Stanyl is highly suitable for applicationsthat involve contact with hot motor oil ortransmission oil. Extensive testing hasshown that Stanyl retains a high degreeof stiffness, good impact resistance,excellent stability and wear properties insuch environments. Even in the moreaggressive environment of automatictransmission oils the decrease inproperties over time is remarkably low.Stanyl displays a clear advantage overPA66 with its superior mechanicalperformance before and after ageing at150 °C for 1.000 hours (see Figure 39).Under normal running conditions, thetemperature of motor oil varies between130 °C and 150 °C, while peaktemperatures of 165 °C or even highercan occur.

At these temperatures the retention ofproperties of the plastics used is crucial.

A successful application of Stanyl inthese conditions is the chain tensioner. Stanyl chain tensioners are commerciallyused by all major automotivemanufacturers worldwide. Therequirements for materials used in chaintensioners are high stiffness at elevatedtemperatures, excellent resistance towear and good resistance to oils.Chain tensioners made of Stanyl wearconsiderably slower than those made ofPA66. Moreover, the high stiffness atelevated temperatures enables thereplacement of the frequently usedsystem (a metal frame with a PA66 toplayer) by a full-plastic Stanyl solution.This results in a very cost-effectivesystem, with operating life three to seventimes longer than that of a PA66 system.

Transmission

Stanyl’s properties remain at anacceptable level in applications whereaggressive oils and high temperatureslimit the use of conventional polyamides.Stanyl can therefore replace expensivematerials such as PEEK and PES.

One example is the use of Stanyl in theguide sleeve that protects the Bowdencable at the point where it is connectedto the transmission. This componentcomes into contact with ATF oil, forwhich peak temperatures of 182 °Chave been measured over a period ofone hour.Stanyl containing 30% glass fibres hasbeen chosen for this application. Stanylis less sensitive to ageing than POM andPA66 and does not undergodeformation at these temperatures.

Stanyl can also be used in othertransmission components, such asthrust washers, gear-shift forks,housings and speedometer gear wheels. Fatigue, limiting pressure velocity (PV),wear and torque resistance are critical inthese applications. The thrust washer,for example, has to absorb highcompression loads arising in thedifferential during acceleration.

Another example is the use of Stanyl inthe self-adjusting clutch ring. The self-adjusting clutch allows pedal pressure toremain constant as the clutch discwears. Its spring loaded thermoplasticring features forward facing wedgeshaped serrations to maintain the propergap between the pressure plate and thecover fulcrums.

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Self-adjustable clutch ring, Stanyl TW200F6.

Bearing cages, Stanyl TW200F6.Oil filter lid, Stanyl TW200F6. Mechanical torsion damper spring seats, Stanyl TW341.

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This results in a consistent feel for thedriver throughout the vehicle’s life. Thisself-adjusting feature eliminatestraditional threaded cable mechanismsfor manual clutches, thus reducingmaintenance and associated costs.Dimensional tolerances for the serrationsare extremely narrow, and Stanyl’s lowpost-shrinkage and high creepresistance at elevated temperaturesmake it the ideal material for the clutchring.

Stanyl is also used in a dual-massflywheel containing flexible elementsconsisting of springs mounted betweentwo plastic seats. This flywheel is usedto dampen vibrations and therebyenhance comfort.Neither PPS (with 40% glass fibres) norPA66 meets the requirements specifiedfor the flywheel regarding creepresistance. The temperature at thefriction surface can rise to 280 °C. Stanylhas clearly demonstrated its suitabilityfor this demanding application.

Engine-management systems

Stanyl’s heat resistance has led to thecommercialisation of a number ofdevices for emission-control systems.These include secondary air supply(SAS) systems.

In integrated safety systems such asABS, TCS (traction control system) anddirect ignition, different kinds ofhousings, sensors, connectors andswitches are used. For reasons of creep,fatigue and vibration resistance at hightemperatures, Stanyl is often selected inthese cases.PA66 often fails to fulfill the hightemperature requirements, whereas PPShas insufficient impact resistance and ismore difficult to process. Compared withPES, Stanyl offers a superiorprice/performance ratio.

Under-the-bonnet applications areparticularly demanding for plastics, withdevelopments like Exhaust GasRecirculation (EGR) reducing automotiveemission levels but increasing operatingtemperatures in the air-intake manifold.

For air-intake manifolds Stanyl is used asan exceptionally strong engineeringplastic to reduce weight and improvefuel efficiency. Considerably lighter thanthe aluminium parts it replaces, Stanylhigh performance polyamide will supportthe key functions of the moderngeneration engine: reliability, durabilityand efficiency at competitive costs.For these applications the high stiffnessof Stanyl up to 220 °C is crucial. This combines with easy injection

moulding, excellent flow characteristicsand short cycle times to give a low finalpart price. Components made fromStanyl can, over short periods of time,withstand temperatures close to thematerial’s melting temperature of 295 °C.

Stanyl is particularly suitable for newengine designs because of its high heatresistance, superior to standardmaterials like PA6 and PA66. As Stanylhas three to four times lowerpermeability to methanol-containing fuelsthan a material like PA66, it is also highlysuitable for use in fuel systems, forcomponents like fuel distributors andactivated-carbon cartridges.

Sensors, switches andconnectors

Stanyl sensors, switches and connectorsare used in areas where hightemperature resistance and toughnessare required, for example in the vicinity ofcatalytic converters, the exhaust or thetransmission.

Air-inlet manifold, Stanyl TW200F6. Automotive connector, Stanyl TW200F6. Positioning switch, Stanyl TW200FM33.

Intercooler end-cap, Stanyl TW200F8.

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Stanyl easily meets these requirementsfor sensors, switches and connectors. Itresists constant temperatures of 150 to160 °C for up to 4000 hours and peaktemperatures of over 200 °C, even incombination with aggressive ATF oils.Besides general temperature,mechanical and chemical requirements,several specific requirements have to bemet, namely temperature cycle tests,vibration tests at various temperaturesand severe long-term tests for tightnessagainst penetration of air, oil, dust andwater at elevated pressures andtemperatures.

Alternators, starters and smallelectric motors

Stanyl applications are also found inelectric motors, alternators and starters.One application is the diode carrier in the

alternator, which converts the alternatingcurrent (generated in the alternator) intoa direct current.Diode carriers typically consist of a metalplate and PES inserts, overmoulded withPA66. These PES inserts are necessarybecause the local temperature is 200 °C,at which the creep resistance of PA66 isinsufficient. Thanks to the use of Stanyl itis possible to integrate the PES andPA66 parts into one Stanyl part. Theresult is a lower final component price.Temperature requirements have also ledto brush holders being manufactured inStanyl instead of PA66.

Tubing

Stanyl TW363, a semi-flexible grade, canbe extruded into thin vacuum tubing thatcan be used for actuation purposesunder-the-bonnet. After metallizationsuch tubing made from Stanyl has beenextensively tested by automotivecompanies for 4.500 hours on lighttrucks and mini vans operating in desertclimates and was found to be superior tothe tubing previously used.

Conclusions

Stanyl is used in under-the-bonnetapplications because of its excellentstiffness, long-term mechanicalproperties and wear resistanceespecially at high temperatures inaggressive automotive environments. Atthe same time Stanyl offers an economicadvantage due to easy and fastprocessing in combination with longerlife time expectancy of the parts. Stanylalso allows increased design freedomand part integration, leading to reducedhandling costs.

Ignition connector. The ignition connector is mounted on top of the engine. Stanylwas chosen here for its heat stability incombination with its mechanicalperformance and chemical resistance.

Radiator clips, Stanyl TW341. Cable channels, Stanyl TW200F6.

Modern diesel engine, Stanyl TW341 chain tensioners exhibit a very low wear.

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Electrical and Electronic applications

General

Electrical industry. Internalcomponents of electrical applicationssometimes encounter hightemperatures. This results from the trendtowards miniaturization or the increase inoperating currents. Consequently thereis an increasing demand for materialswith:- high heat resistance- high stiffness at elevated temperatures- low creep at elevated temperatures.

In applications such as electric motorparts, internal parts of circuit breakers,wire-wound components, e.g. bobbinsand switches, Stanyl offers cost-effectivesolutions and can easily compete withmaterials such as PPS, PEI, PES, PPA,and LCP in terms of price/performanceratio. As a result of its outstandingintrinsic properties Stanyl has beensuccessfully applied in the followingapplications and end-markets:- connectors- circuit breakers- wire-wound components- SMD components- switches- electric motor parts- computers and peripherals- telecommunications- electrical and domestic appliances- consumer electronics.

Table 5. Stanyl out performs well-known polymers such as LCP and PPS.

Electronics industry. The continuingtrend towards miniaturization of printedcircuit boards leads to even smallersurface-mount devices (SMD) withfurther reduced wall thicknesses. Theseelectronic components are moresusceptible to the high peaktemperatures involved in modern reflow-soldering techniques (see Table 5).

For these SMD applications, materialswith a high heat distortion temperaturemust be used. Stanyl combines a heatdistortion temperature (HDT) of 290 °Cwith excellent toughness andoutstanding flow. It provides economicalsolutions and meets the latest designrequirements for all kinds of endmarkets.

Resistance against IR reflow soldering*Material Maximum temperature (°C)

of a standard IR reflow curve250-260 260-270 270-280 280-290

Stanyl TE250F6 30% V-0Stanyl 46HF5040 40% V-0PPS 40% V-0PA 6T 30% V-0PPA 33% V-0PET 30% V-0PCT 30% V-0LCP 30% V-0

No deformation

* Determined at thickness of 0.8 mm, dry as moulded Slight deformation

Deformation

Glass fibrereinforce-ment

UL94classifi-cation

Stanyl® PA46 High Flow

Stanyl High Flow 46HF5040, a glassfibre reinforced, flame retardantpolyamide 46, is the first grade of a newgeneration of Stanyl. This gradecombines the high strength andtoughness levels of the standard Stanylflame retardant materials with excellentflow characteristics comparable or evensuperior to Liquid Crystal Polymer (LCP)(see Figure 4), a material often used forInformation and CommunicationTechnology (ICT) equipment. The StanylHigh Flow grade can replace LCP,resulting in cost savings of up to 50%.

RIMM connector. Stanyl 46HF5040 (High Flow) is used for the new generation memoryconnectors. The optimal combination of “flow like LCP” and mechanicalproperties “better than LCP” enables a more cost-effective solution withoutgiving-in on properties.

Stanyl High Flow 46HF5040 has anUnderwriters Laboratories (UL) 94 V-0rating at 0.8 mm for all colours, includinga UL approval for 50-100% regrind use(UL yellow card file number for Stanyl isE119177 see Table 7). It offers hightoughness, even in dry-as-mouldedconditions. The weld-line strength of thenew grade is significantly higher thanthat of LCP, enabling connectormanufacturers to post-insert pins directlyafter injection moulding without the riskof cracking, thereby reducing rejectlevels.Components made of Stanyl High Flowmaintain their dimensional integrityduring reflow soldering up to 280 °C dueto the extreme high stiffness of thematerial at these temperatures. This isespecially important for the new lead-free soldering techniques. While LCP isoften specified for such components, thecost of LCP is significantly higher thanthat of Stanyl. This costly “overdesign”can now be eliminated because Stanyl’snew High Flow series, specifically Stanyl46HF5040, meets the end users’performance requirements and canreduce part costs by as much as 50%.

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Figure 4. Flowimprovement StanylHigh Flow grades.

LCP1 = lower flow, highermechanical properties, LCP2 = higher flow, lowermechanical properties.

Figure 3. HDT versus solder temperatures.

Stanyl is being used for the SMD version of this applianceconnector.

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Challenges for the E/E industries

Increasing solderingtemperatures. The use of lead-freesolder will cause an increase in thetemperature profile of the solderingovens. A rise of approximately 20 °C canbe expected, leading to peaktemperatures in the solder processbetween 260 and 280 °C. Stanyl with itsheat distortion temperature (HDT) of 290°C (see Figure 3), will retain itsdimensional integrity at solderingtemperatures of 280 °C, which is higherthan the HDT of most of the other highperformance materials.

Connectors

Stanyl meets the requirements for variousconnector designs such as modularjacks, shrouded headers, powerconnectors, fine-pitch connectors,breakaway connectors, sub-miniature D-connectors, memory-card connectors,edge-card connectors, ZIF-PGAconnectors, memory module connectors(DIMM, DDR-DIMM, RIMM), and varioustelephone-handset connectors. All ofthese connectors can be made of Stanylgrades.

Cycle time. With Stanyl an overall cycletime reduction of up to 30% can beachieved compared to other polyamidesand polyesters (including PCT), resultingin a clear economic advantage.Compared to LCP a similar cycle timecan easily be achieved. It has beendemonstrated that the cycle time of anedge-card connector, originally madefrom PPS, can be reduced by 50%,without any flash being produced andwith dimensional specifications being met.

The shrinkage of Stanyl is close to thatof commonly used polyesters andpolyamides. Thus existing tools can beused without any adjustments.

The on-going miniaturization ofconnectors means that wall sections arebecoming thinner and more complex.Stanyl’s excellent flow enables sectionsas small as 0.1-0.2 mm to be filledwithout any problem.

Stanyl is specified in surface-mount fine-pitch connectors with pitches of 0.3 mm.These are used in products such asprinters, video cameras, and lap-topcomputers.

Pin headers. Pin headers come in various lengths. The use of Stanyl enabled customers to produce all versions (some are up to 200mm long) with the same high quality at competitive costs.

Figure 5. Positioning of 30%glass fibre reinforced, flame retardantthermoplastics.

Even the best-flowing grades of Stanylshow no flash, in contrast to many otherhigh flow polymers, such as PPS.

Pin insertion and pin retention.Stanyl’s combination of good weld-linestrength (by far superior to LCP) andexcellent tensile elongation (see Figure 5), prevents the introduction ofmicro-cracks during the pin insertionprocess even when this is performeddirectly after moulding. The absence ofthese micro-cracks and Stanyl’s highstiffness at the soldering temperature,guarantees the best pin retention force,also after the soldering process.

Snap-fits, latches and pegs.Stanyl’s toughness allows designersgreater freedom in the design of snap-fits, latches and pegs. In the case ofhigh-current connectors, safeconstruction is needed to preventaccidental separation of matingconnectors. Stanyl is chosen because itcombines high stiffness with hightoughness, especially in thin sections.This ensures excellent behaviour duringrepeated mating cycles.

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UL 1446 classes Stanyl gradesB 130 °C TE350, TE250F6, TE250F8, TE250F9,

TW250F6F 155 °C TE200F6, TE250F6, TE250F8, TE250F9,

TW300, TW341, TW200F6, TW250F6H 180 °C TE200F6, TE250F6, TE250F8, TE250F9,

TW200F6, TW250F6

Moisture absorption. Like allpolyamides, Stanyl absorbs moisturefrom the environment. However, it offersgrades with the required dimensionalstability even when subjected to tropicalenvironments. These grades meet eventhe stringent specifications required forDDR-DIMM sockets up to an overalllength of 150 mm.

LCP mould. In practice LCP can bereplaced without major modification ofthe existing moulds. The modestshrinkage of Stanyl in the flow directionwill be compensated by the dimensionalchange due to moisture absorption.This, in combination with its SMDresistance and easy processing (goodflow, low tool temperature, fast cycling),makes it an outstanding cost-effectivealternative for LCP.

Table 6. UL 1446 insulation system recognition for Stanyl.

SIM connectors. The use of Stanyl instead of LCP in aSIM connectors created an interesting cost-saving of 30-70% on material cost, without giving-in on properties.Stanyl can often be used in tools cut for LCP.

Stanyl, a cost-effective solution for wire-wound components.

Wire-wound components

UL 1446. Stanyl’s UL 1446classification guarantees that systemswith Stanyl as insulation material willwithstand heat generated during bothnormal operation and overloadconditions of an electric motor or bobbin(see Table 6). This system approvaldecreases the approval cost and timedrastically.

Bobbins. Many different wire-woundcomponents are used in transformers,filters, relays and electric motors.Bobbins are either of the standard pin-through-hole or the surface-mount type.Stanyl is chosen for these applicationsfor reasons pertaining to the productionprocess e.g. winding and dip soldering.

Winding. Stanyl’s high stiffness andtoughness improve the quality of thebobbin and diminish the reject level afterwinding. When thermosets or PPS areused the reject rate can be high due tothe brittleness of these materials.Stanyl’s superior creep performancemakes it better than other polyamidesand PPA’s when it comes to with-standing heat-treatment procedures(such as encapsulation) on wire-woundcomponents. For example, it shows asuperior creep performance at 140 °Cunder a load of 20 MPa.

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Dip soldering. After winding, the wireis soldered to the connecting pin. This isdone by passing the pin through a solderbath. The solder bath operates attemperatures between 380 °C and 500 °C. Although the plastic itself is notin direct contact with the heat source,heat conducted via the pins may softenthe plastic and allow the pins to move.Stanyl performs better in this respectthan the widely used PBT, PA66 or PC.PPS is too brittle and shows too muchflash.

Eliminating wrapping film andpotting. Before encapsulation,polyester film may be wrapped aroundthe coil. Stanyl has enabled designers toleave out this extra production step byreplacing the film by hinges which areintegrated with the bobbin, with sectionsof less than 0.3 mm. The excellent flowof Stanyl enables the films of these thinflaps to be integrated in the bobbins.

Electric motors

The trend in E-motors is to miniaturize.While power supply and capacity remainthe same or increase, internaltemperatures may rise significantlydepending on the design. Overloading orblocked rotors can lead to temperaturesrapidly exceeding 250 °C. Safetymargins may be required for adequatefunctioning.

Stanyl can be found in various parts ofan electric motor including endlaminates, brush holders, gears and endbrackets and (end) frames withincorporated brush holders.

End laminates. The winding processexerts a considerable stress on the endlaminate. Brittle materials such asthermosets, polyesters and PPS need ahighly controlled winding process toprevent cracking.Production costs are consequently high.The high toughness of Stanyl offersimproved reliability and lower productioncosts. After winding, the load on the endlaminate can be permanent, requiringhigh creep resistance at elevatedtemperatures. In blocked-rotorsituations, peak temperatures of morethan 250 °C may occur. Whencombined with a load, these may resultin deformation of the plastic, leading tomalfunctioning of the motor. The highHDT of Stanyl (290 °C) prevents theoccurrence of such deformations.

Brush holders. The use of brushesleads to significant power loss at highcurrents. In combination with internalfriction between the brushes and thecommutator, this can result intemperatures exceeding 220 °C. Only alimited number of materials canwithstand these conditions. Initially thermosets were used, but highproduction costs led to the search foralternative thermoplastic materials. PPSwas found to be too brittle. Stanyl offersan ideal combination of high stiffness atelevated temperatures and toughness,giving greater reliability at lower cost.

End laminates: Stanyl is used in vacuum cleaners, lawn mowers and washingmachine motors for end laminates.

Stanyl® PA46 in circuit breakers

Stanyl has successfully replaced metal,thermosets and more expensivematerials such as PEI, PES and PPS forseveral internal parts of circuit breakers.For these applications, a high heatresistance, low creep at hightemperatures and outstandingmechanical properties (toughness) arerequired. The high peak temperatureresistance of Stanyl is an additionaladvantage in Miniature Circuit Breakers(MCB) parts that are exposed to the hightemperature switching arc.Due to its good balance of strength andductility, flame retardant Stanyl is alsobeing used as enclosure material forMCB’s and Residual Current Devices(RCD’s), especially in high performance

Mobile phone connectors. Stanyl (TE250F6,46HF5040) is the material for a cost-effective solution inmobile phones.

applications where other polyamides failto pass the final short circuit tests. Inhigh current switches, Stanyl is used inparts that are subject to high mechanicalshock during switching operations,where zero failure after severalthousands of switching cycles isrequired.

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Description Grade Colour Minimum UL 94 RTI ºC1) H H H D Cdesignation thickness W A V 4 T

El WI WOI I1) I1) T 9 I1)

mm R1) 51)

Unreinforced TE300 NC 0.9 V-2 130 - - 3 0 0 5 0TE341 NC, BK 0.75 V-2 130 - - 3 0 - - 0TW300 NC 0.75 V-2 150 115 130 3 0 1 6 1TW341 NC, BK 0.75 V-2 150 115 130 3 0 1 6 2TW371 NC 1.5 HB - - - - - - - -TW441 NC 0.75 V-2 - - - - - - - -

Flame retardant TE350 NC, BK 0.75 V-0 130 110 120 1 0 1 7 2Glass reinforced TE200F6 NC 0.9 HB - - - 0 0 0 5 1

TW200F6 NC 0.9 HB 140 140 140 0 0 0 5 2TW241F10 BK 0.75 HB - - - - - - - -TW271F6 NC, BK 0.75 HB - - - 0 0 3 - 2

Glass reinforced, 46HF5040 2) All 0.75 V-0 140 130 130 0 0 1 7 2Flame retardant TE250F3 NC, BK 0.9 V-0 130 110 120 1 0 1 7 3

TE250F6 2) All 0.35 V-0 140 130 130 0 0 1 6 2TE250F8 2) All 0.75 V-0 140 130 130 0 0 0 7 2TE250F9 2) All 0.75 V-0 140 130 130 0 0 0 7 2TW250F6 NC, BK 0.75 V-0 140 140 140 0 0 1 7 3

Glass reinforced, TS250FK33 NC, BK 0.75 V-0 - - - - - - - -Mineral reinforced

1) These data are for 3 mm thickness2) Recognitions for regrinds are available (up to 100%)

Detailed and up-to-date UL-data can be found on the internet website ofUnderwriters Laboratories Inc.http://data.ul.com

UL recognitions

Table 7. Underwriters Laboratories yellow card file E 119177 for Stanyl grades.

Earth leakage circuit breakers. Stanyl offers an excellent balance of flowand mechanical properties at very lowwarpage levels.

Industrial high current circuit breaker.Stanyl has succeeded in replacingthermosets in this demanding application,where other thermoplastic materials fail tomeet the requirements.

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Consumer durables and other applications

The clear advantages over other plasticsthat Stanyl offers in personal careproducts, kitchen and householdappliances, power tools and gardenappliances are:- resistance to high temperatures- high stiffness at elevated temperatures- excellent fatigue resistance at elevated

temperatures- toughness- high wear resistance- low friction.

Kitchen appliances

Metal or wooden kitchen spatulas areincreasingly being replaced by plastics,for greater design freedom and forbacteriological reasons. If thetemperature requirement is not too high,PA66 is used. However, in hot oil PA66meets its limitations.Stanyl shows no deformation up to 280°C. Stanyl TE grades comply with thefood-approval legislation of mostEuropean countries.

The safety controls in electric kettles andovens are based on a thermostatcombined with a switch. Duringoperation, temperatures surrounding thebi-metal may exceed 275 °C. As a resultof its high heat distortion temperature,combined with the absence of flash andgood toughness for snap-fits, Stanyloutperforms PPS in this application.

For applications where not only heatresistance but also “cosmetic”appearance (visible parts) are important,e.g. oven knobs and toaster parts,unreinforced Stanyl is the best solution.

Gas curler, Stanyl TW200F6. Engine grid for small petrol engines (e.g. trimmers, chain saws).

Kitchen spatulas, Stanyl TE300.

Crank shaft saddle, Stanyl TW200F6.

Power tools and gardenappliances

Stanyl’s high stiffness at elevatedtemperatures allows the replacement ofmetal components. This, combined withparts integration, gives a considerableweight reduction. Examples ofapplications are: electric motor parts,crank shafts, grid covers and heatshields.

Other applications

Stanyl has been chosen for office chairseat adjustors because of stiffness,toughness, wear and low friction.Grids of electric fan heaters requirestiffness at high temperatures andtoughness. The trend is to design morecompact heaters with higher heatingcapacities. Stanyl outperforms the otherhigh heat resistant thermoplastics.

Thermostatic control for water kettle, Stanyl TE250F6.

Processing with Stanyl

Typical shrinkage values

Shrinkage values parallel andperpendicular to the flow for commonStanyl grades are given in Table 8.

Often the exact shrinkage levels cannotbe predicted. For precision articles, it isadvisable to start with a prototypemould. If this is not possible, the toolcavity should be under- or oversized sothat later corrective adjustments areeasier to make.Three major factors have to beconsidered:

Part dimensions

Dimensional aspects- mould manufacturing tolerances- thermal linear expansion of the mould

between 23 °C and the mouldingtemperature Tm.

Processing- mould shrinkage- post-shrinkageOperation conditions- water uptake- thermal linear expansion of the

moulded part.

Shrinkage of mouldings

The level of shrinkage depends onseveral factors and varies with the gradeof Stanyl. In general the shrinkagebehaviour of Stanyl is similar to that ofPA66.

Processing shrinkage. The level ofshrinkage is mainly determined by: - grade of Stanyl- holding pressure- holding time- mould temperature- gate position- glass fibre orientation.

The holding pressure (see Figure 6) incombination with holding time has thegreatest influence on mould shrinkage.

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Grades Shrinkage (%) 2 mm wallthickness

flow direction // ⊥unreinforced 2 2flame retardant unreinforced 2 2glass fibre reinforced (30 %) 0.3-0.5 0.9-1.3flame retardant glass fibre reinforced 0.2-0.4 0.7-0.9

Table 8. Typical shrinkage values.

Figure 6. Influenceof holding pressureon shrinkage 1).

Figure 7. Influenceof mouldtemperature onshrinkage 1).

1) Unreinforced Stanyl (UF), after 14 days storagedry as moulded:- mould dimensions 80x80x2 mm- mould temperature 80 °C- cooling time 30 s- holding pressure 325 bar.

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By varying these, dimension correctionsare possible, but internal stresses maybe introduced. This has a negativeinfluence on aspects such as fatigue.Internal stresses can be reduced byusing a “stepped” holding pressureprofile. Depending on the shape of thearticle and the gate, optimizing theholding pressure is very important.Control parameters are weight anddimensions.Increase of the mould temperature (seeFigure 7) shows a small increase of theshrinkage level and reduction of post-shrinkage. The influence of cooling time(see Figure 8) on Stanyl’s shrinkage levelis small.

Mould design variables. Designvariables are:- length and diameter of sprue runner

and gate - position and type of gate- wall thickness of the moulding.

In general, smaller gates and runnersresult in higher mould shrinkage. This isbecause the premature freeze-off of thematerial in the gate prevents furtherpressurisation necessary to compensatefor mould shrinkage. Thicker walls givehigher shrinkage. The influence of wallthickness on shrinkage (mould- andpost-shrinkage together after 14 days,dry as moulded) is shown in Figure 9.

Warpage

Like any other semi-crystallinethermoplastic, Stanyl has a highertendency to warp compared toamorphous materials. The combinationof the anisotropy (injection mouldinginduced orientation) and shrinkageresults in a higher warp sensitivity.

Figure 9. Influence of wall thickness on total shrinkage 2).

Figure 8. Influenceof cooling time onshrinkage 1).

2) Unreinforced Stanyl(UF), free shrinkage testplate, mouldtemperature 80 °C.

Two major mechanisms cause warpage:- differences in cooling rate- anisotropy (crystallinity, reinforcement).

Major factors decreasing warpage are:- balanced cooling- more isotropic materials- symmetrical part design (wall

thickness, ribs, etc.)- cavity balance and gating (gate

locations and dimensions).

Modular fuel pump and sender assemblies.

Conditioning of Stanyl® PA46components

To accelerate the realisation of thespecified dimensions or to achieveincreased toughness, it may benecessary to condition the components.

Water absorption. The equilibriumwater content at 23 °C/50% RH is:- 3.7% for unreinforced Stanyl grades

and- 2.6% for 30% glass fibre reinforced

grades.

There are several conditioning methodsfor accelerating water absorption: - the ISO 1110 (1987) standard

indicates that accelerated conditioningat 70 °C/62% RH results in the samewater content as equilibrium moisturecontent at room temperature/50% RH

- a simple method is immersion of thecomponents in water (50-80 ºC) untilthey have reached the equilibriumcontent determined by weight at 23 °C/50% RH followed by at least 2 days conditioning.

- the components can be packed in PEbags, with 3.7% respectively 2.6% (byweight) of water added and the bagssealed. This method is more time-consuming.

Influence of moisture uptake ondimensions. Although Stanyl absorbsmore moisture than PA66, the resultingdimensional change at equilibrium is of asimilar order (see Figure 10). Due to theeffect of water absorption, thedimensions will increase (see Figure 11).These effects should be taken intoconsideration when designing themould.

More detailed information about designguidelines can be found in the brochure“Designing with DSM EngineeringPlastics”.

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Figure 10.Dimensional changein length directiondue to moistureabsorption.

Figure 11. Dimensional changein flow directionversus relativehumidity.

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Equipment

Injection moulding machine

Stanyl can be processed on standardreciprocating screw injection mouldingmachines.

Injection unit. For best results, thepreferred shot weight should bebetween 50 and 65% of the maximumplasticizing capacity. The capacity of theheater bands should be sufficient (4-5 W/cm2 of the outside barrel surface)to ensure enough heat is transferred intothe material.

Screw geometry. The feedperformance and the plasticizing of thegranules are, to a high degree,determined by the screw geometry. Athree zone screw, with non-return valve,of the following geometry, isrecommended: - a L/D ratio of at least 20; - a channel depth ratio from 1:2 to 1:2.5; - a channel depth, in the metering zone,

of 0.06-0.07 D; - a constant pitch of 1 D; - feeding compression and metering

zone lengths of 0.6 L, 0.2 L and 0.2 Lrespectively.

Screws that are too short haveinsufficient melting and homogenisingcapacity. This will cause high pressure inthe compression zone, resulting inexcessive wear and shear and screwstall, and may lead to unmolted particlesin the end product.

Non-return valve. The non-returnvalve plays an important role incontrolling the pressure and must becompletely closed in order to maintainpressure throughout the moulding phase.

Figure 12. Nozzle design.

A worn valve is always apparent from thescrew’s tendency to continue to moveforward during the holding pressurestage. A badly worn or broken valveshould be replaced promptly. It isimportant when reinforced Stanyl ismoulded to keep a regular check on thefunction of the valve.

Nozzle design. Open nozzles have theadvantage of no flow restrictions whichcould damage the glass fibre length ofreinforced grades. The absence of deadspots is also an advantage. The designand temperature control should,however, be of a high standard to avoidfreeze-off or drooling (see Figure 12).If necessary, different types of shut-offnozzles can be used. However, pressure losses during mouldfilling and packing and degradation ofthe material are encountered.

To minimize such losses use ahydraulically operated shut-off typenozzle.

Important design features is a largesurface area, completely covered withheater bands of sufficient output. Theseheater bands should be controlled via athermocouple placed near the tip of thenozzle because the aim is to have anaccurate temperature control of thenozzle tip. The temperatures should beset at a level where the material justfreezes off when the nozzle retracts fromthe mould. The conical tapered openingfacilitates withdrawal of the frozen sprue-end from the nozzle.

Bus bar connector. This connector is used in power supply. Stanyl TE250F6has been chosen for its right combination of properties: high toughness for thelocking system; V-0 and a long term thermal stability at 160 °C.

Screw/barrel steel. Processing ofglass fibre reinforced and/or flameretardant engineering plastics onstandard screw and barrel assembliescan cause considerable wear andcorrosion.Manufacturers of injection mouldingequipment recommend the use of ionnitrided steels when glass fibre and/orflame retardant engineering plastics arebeing processed.For GF/FR Stanyl this wear can bereduced to acceptable limits by usingcoated screws/barrels and non-returnvalves.

Moulds

General features. Moulds used forStanyl are designed in a similar manneras those used for other thermoplastics.Stanyl is processable in existing mouldsdesigned for PA, PPA, PPS, PET, PBT. If an existing mould is used, make surethis mould is suitable for operating withthe necessary temperatures (with regardto slides, cores, etc.) and differences inshrinkage. Whenever possible, sectionthicknesses should be uniformthroughout the component in order togive uniform cooling shrinkage, stressdistribution and packing. Avoid internalsharp corners to reduce high stressconcentrations and subsequentweaknesses. The dimensional tolerancesmentioned in DIN16901 for aliphaticpolyamides are applicable to Stanyl.Compared to this DIN norm, experienceindicates that the tolerance of 0.15%can be reduced to 0.05%, within the sizelimits of 10-100 mm. This, however,requires accurate manufacturing of themould and optimal and reproducibleprocessing.

Injection

Sprues. Sprues have to be tapered toprevent sticking in the bushing. The totaldraft angel should be between 2° and3°. Sprue extractors should be taperedin the opposite direction (5°). The lengthof the sprue extractor should beapproximately equal to its diameter.

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Runners. As processing temperaturesare not far above the crystallisationtemperature, runners and gates must beof adequate size to prevent solidificationof the material before reaching thecavity. The diameter of the runners canbe empirically estimated from maximumthickness of the part plus 1.5 mm. A more accurate result can be obtainedusing flow simulation programs.

Gating. The position and sectional areaof the gate must always be carefullylocated from the point of view of the finalproperties of the part rather than simplyease of construction.When possible, gates should bepositioned at the thickest section of thecomponent. The gating is normallyplaced at a line of symmetry of theproduct. Be aware of the fact thatweldlines should not occur where loadsare involved. If the gate is too small andthe material freezes prematurely, it willnot be possible to pressurize the mouldcavity further, resulting both in mouldfilling problems as well as stresses in thearea of the gate.The gate diameter should therefore be atleast 50% of the component wallthickness, with a short land length tohelp overcome void formation, sinkingand poor dimensional stability.For tunnel gates (see Figure 13) theminimum recommended diameter is 1.0-2.5 mm (approx. 75% of the wallthickness).

Hot runners. When for instance longflow paths are involved, a hot runnersystem could be used. When using a hotrunner system, an open, externallyheated system with a small front torpedoor shut-off valves is recommended. The hot runner design should bestreamlined to avoid dead spots.

Figure 13. Tunnel gate.

Ignition connector, Stanyl TW200F6.

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It is important that good thermal controlis assured throughout the runnersystem, particularly at the nozzle gatesto avoid nozzle stringing or freezing.Each nozzle tip should be controlled bya separate temperature control device toensure smooth production.To provide even temperatures, themanifold block needs enough heatingpower and separate heating circuits.

Venting. Ideally, the mould should haveventing at several points around thecavity. The minimum requirement is tohave adequate venting at the end of theflow path. Due to the low viscositycombined with the high rate ofcrystallization of Stanyl, a depth of 0.01-0.02 mm for the venting channelsis sufficient. To improve the venting thechannels should be enlarged after 2-3mm.Ejector-pins, moving cores and mouldinserts can be produced with aclearance of 0.01-0.02 mm so thatoptimum venting is guaranteed.For multi-cavity moulds with aconventional runner lay-out, it ispreferred to vent also the end of therunner in the mould parting line (depth0.1 mm, length 3 mm).

Flow behaviour. A material’s flowbehaviour depends on several factors:- melt temperature- mould pressure- melt viscosity- injection pressure and injection rate- runner and gate dimensions.

Figure 14. Spiral flow lengthof Stanyl GFgrades; spiralthickness 1 mm,mould temperature 80 °C (influence ofglass content).

Figure 15. Spiral flow lengthof Stanyl GF FRgrades, spiralthickness 1 mm,mould temperature 120 °C (influenceof glass contentand melttemperature).

End laminate in electro motors.

Stanyl has very good flow properties. Itwill readily fill moulds with long orcomplicated flow paths with goodreplication of the mould surface details.However, because it has a high rate ofcrystallization, it solidifies rapidly and fastinjection rates are necessary.

The effect of injection pressure and melttemperature on flow length is illustratedin Figures 14, 15. Figure 16 shows theinfluence of wall thickness.

Ejection. Stanyl does not stick to themould surface and has good ejectionproperties. The component should havetapered walls and ribs with a 1° taper forStanyl UF and 0°-301 mm for Stanyl GF.Parts with less draft angle can bemoulded from Stanyl if the mould isprovided with extra ejectors.

Temperature control. The quality ofthe components and the degree towhich their properties can bereproduced, depends amongst others,on a uniform cavity wall temperaturedistribution.Mould insulation plates arerecommended to prevent heat transferfrom the heated mould to the injectionmachine. The use of such plates offersmore precise mould temperatures and inaddition energy savings.

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Figure 16. Spiral flow length ofStanyl UF asfunction of wallthickness; mouldtemperature 120 °C.

Mould steels. Stanyl without flameretardant additives can be processed inmoulds made of standard tool grades.For flame retarded Stanyl grades, it isnecessary to use steel containing atleast 12% free chromium.

For reinforced Stanyl grades hardenedsteel prevents wear. Required hardness:56-60 HRc.

Inserts

Use of metal inserts. Metal insertscan be overmoulded with Stanyl. Largerinserts require preheating to 80-120 °Cto avoid the creation of local stresseswhich can lead to cracks or brittlefracture. If cracking occurs, the wallthickness surrounding the metal insertshould be increased to absorb thestresses. The inserts should be clean,free of oil and grease and without sharpedges.

Safety

Under normal conditions, Stanyl doesnot present a toxic hazard through skincontact or inhalation. During processing,contact with the polymer melt andinhalation of the fumes should beavoided. A Material Safety Data Sheetcan be requested from the DSM productadministration department.

Chain guides and tensioners, Stanyl TW341 and TW241F10 (base).

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Material handling

Packaging

Stanyl is supplied in sealed, airtight,multi-layer 25 kg bags or 1000 kg inoctapacks. Bags are supplied oncomplete pallets of 1375 kg and arewrapped in plastic. The bags should onlybe opened immediately prior toprocessing.

Storage. When the material is stored ina relatively cold warehouse, it isrecommended to condition the materialby placing the bags near the processingunit 24 hours prior to its use. This willprevent moisture condensing on thegranules after the bag is opened.The hopper should not be filled withmore material than is sufficient for fourhours of production.When a bag has been opened and thecontent has not been used completely,the bag should be closed and sealedcarefully to prevent contamination andmoisture pick up.

Drying

Every batch of Stanyl is tested formoisture content and viscosity. Acertificate with the relevant batch datacan be delivered with the materials.Stanyl is packed at a maximum moisturecontent level of 0.1%.For critical applications, therecommended moisture content is0.05% or less. Higher levels can have anadverse effect on both flow andmechanical properties. When bags havebeen opened, or have been damaged, itmay be necessary to pre-dry the materialto a moisture level of less than 0.1% (seeFigure 17).It is advisable to dry Stanyl withdehumidified air dryers according to

Moisture content Pre-drying of Stanyl3):time temperature

0.05-0.2% 2-4 h 80 °C0.2-0.5% 4-8 h 80 °C> 0.5% 24 h 105 °C

100 h 80 °C

Table 9. Moisture content and advised drying conditions.

Figure 17. Drying of wetStanyl grades 3)4)

Table 9. The key requirement of thedryer, however, is its ability to maintain adew point between -40 and -30 °C. Dewpoints above this level do not facilitatedrying.

Vented barrel. At high temperatures orlong residence times, wet material candegrade due to hydrolysis, which will leadto a drop in molecular weight. A ventedbarrel does not effectively reduce a highmoisture content in Stanyl. For thisreason, we do not recommend ventedcylinders for processing moist Stanyl.

3) Drying in a pre-heatedair circulated oven (dew point ≤ -30 ºC).

4) After conditioning for 42 days at + 23 °C and50% relative humidity (= starting point curve).

The packline where the final Stanyl product is packed in 1000 kg octabins forshipment to customers.

Use of regrind

The standard practices using regrind,also apply to Stanyl:- clean, non-contaminated regrind- low dust content (use sieves to

remove dust)- no thermally degraded material- pre-dried material, moisture content

< 0.05%- no mixtures of different types of

Stanyl.

To avoid moisture pick up, it is advisableto regrind the sprue immediately afterprocessing, mix it with virgin materialand feed it back into the hopper.

Critical applications should be producedwithout regrind.“Parts shall not be moulded frommaterial that contains more than 25%thermoplastic regrind by weight, unlessthe result of a separate investigationindicates acceptable performance for thespecific part.” (Underwriters LaboritiesInc. UL746D).Regrind can cause colour changes andthe flow characteristics of the materialcan also be affected.

Production start up

Start production with a clean injectionmoulding unit. Cleaning can best becarried out by purging with HDPE (MFI 0.2).

To start the injection moulding process,the following procedure should be used:- set the cylinder temperatures as

recommended in Figure 18. Make surethe injection unit has reached thesetemperatures, to prevent high torqueloads on the screw. Recommendedhopper base temperature is 30-80 °C

- set mould temperatures to 80-120 °C- make sure the hopper is clean and

filled with dry Stanyl- start the injection cycle with a short

shot and optimize the conditions.

Plasticizing

See also page 28 for Stanyl High Flowgrades.

Melt temperature/residence time.In order to establish the optimumprocessing temperatures, one should beaware of the upper and lowertemperature and time limitations forprocessing Stanyl. Like otherpolyamides, Stanyl shows severedegradation at melt temperatures above330 °C, also at short residence times. Atlower temperatures, the allowableresidence time depends on thetemperature (see Figure 19). To generatecompletely molten materials, the melttemperature should always be above300 °C. Optimum mechanicalproperties, are achieved when Stanyl isprocessed with a melt temperaturebetween 310-320 °C, for High Flowgrades 315-330 °C and a residence timeof less than 6 minutes.

A non-homogeneous melt may affect theproperties of the material negatively,especially its toughness and fatiguebehaviour.

The melt temperature depends on thecylinder temperatures settings, thescrew configuration, the screw speedand the back pressure. Therefore, it isessential to measure the actual melttemperature after the injection mouldingprocess has been running on automaticcycle for some time and the processingconditions have stabilized.The residence time is defined as the timethat the material needs to get from thehopper through the injection mouldingmachine and into the part.

Cylinder temperatures. Semi-crystalline materials require additionalenergy compared to amorphousmaterials in order to fully melt theircrystalline structure.Due to its high melting point and highcrystallinity, Stanyl needs a relatively longfeeding zone. In order to compensate forthis on screws which have a shortfeeding zone (1/3L) the following stepscan be taken:- an almost uniform temperature profile

with, in extreme cases, a highertemperature setting near the hopperthan the nozzle temperature

- pre-heat the material in the hopper(max. 80 °C and use pre-dried air)

- limit the cooling at the hopper base,30-80 °C.

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Stanyl Mould Melt Nozzle Front Center RearStandard grades 80-120 305-320 280-300 300-320 300-320 280-320 °CHigh Flow grades 60-120 315-330 280-300 315-330 310-325 280-310 °C

Figure 18. Standard moulding temperatures.

27

Starting temperatures as shown inFigure 18 are recommended.

Plasticizing problems. Whenproblems occur, such as unmoltengranules or a grinding noise is heardduring plasticizing, it may be necessaryto increase the temperature settings atthe feeding zone. The addition of nomore than 0.1% of a lubricant based onPE, can be beneficial when irregularplasticizing occurs. The use of stearates(for example Ca-stearate or Zn-stearate)is not advised since the molecular weightof Stanyl may drop during processing.

Screw rotation speed. Like mostaliphatic polyamides, Stanyl hasexcellent flow properties due to itsrelatively low melt viscosity. For Stanyl ascrew rotation speed should be selectedto give a plasticizing time that is justwithin the cooling time.In Figure 20 the limits of the screwrotation speed are shown in relation tothe diameter of the screw. Thecircumferential speed of the screwshould not exceed 0.25 m/s for smallscrews and 0.20 m/s for largerdiameters.With glass reinforced grades, careshould be taken to prevent the reductionof the glass fibre length.

Back pressure. A back pressure of50-75 bar effective (10-25 bar for HighFlow grades) is recommended forprocessing Stanyl to homogenise themelt and to prevent air or gasentrapment in the melt, which wouldotherwise cause voids or streaks.A too high back pressure (± 200 bareffective pressure) can cause anincrease in plasticizing time (usuallyresulting in a longer cycle time),unnecessary nozzle drool and areduction of the glass fibre length.

Figure 19. Processing windowfor standard Stanylgrades.

Figure 20. Screw speed forstandard Stanylgrades.

Processing Stanyl® PA46 HighFlow

Due to its high flow character, StanylHigh Flow (46HF5040) is less sensitive toshear heating and should be processeddifferently from the standard Stanylgrades. The best results, both formechanical properties and flow, havebeen obtained using actual melttemperatures around 325 °C. Due to thelow shear heating, this can only beachieved by increasing the barreltemperature settings in the compressionand metering zone. As for regular Stanylgrades, high injection pressures givebetter end-product performance.

An example of settings used for46HF5040 (using an injectionmoulding machine with a 22 mmscrew diameter):- temperature profile from hopper

to nozzle: 290-295-305-315-315-315 °C (or 325-330 °C incompression/metering zone)

- back pressure: 25 bar specific - rotation speed: max. 340 rpm- injection speed: max 100 mm/s- holding pressure: < 350 bar

specific.

As a result of its high flow, injectionpressures will be reduced up to 50%and less warpage will occur (less built-instresses).

28

Problems that may be encounteredwhen using standard Stanyl settings forHigh Flow grades are:- a large variation in dosing time- variations in injection pressure- drooling from nozzle- low melt temperatures (< 300 °C).

The variations in dosing time andinjection pressure can be overcome bydecreasing the back pressure,decreasing the temperature of thefeeding zone and increasing the screwspeed compared to standard Stanylsettings. Because of the reduced shear,the final melt temperature will be lowerusing the same barrel settings. When themelt temperature decreases below acritical level (300 °C), it may result inpoor mechanical properties caused byan inhomogeneous melt. To avoid this,the temperature setting of thecompression and metering zone shouldbe increased. Drooling from the nozzlecan be adjusted by lowering the nozzletemperature. Beware not to lower thenozzle temperature too much as it againmay lead to an inconsistent dosingbehaviour or premature freezing of themelt.

Injection phase

As Stanyl sets up fast in the tool, highinjection speeds are required in order toobtain a good surface finish. Adequatemould venting is necessary to avoidburning (due to self-ignition) at the end ofthe flow path.

SIM connectors. The use of Stanyl instead of LCP in a SIMconnector created an interesting cost-saving of 30-70% onmaterial cost, without giving-in on properties. Stanyl can oftenbe used in tools cut for LCP.

Since Stanyl is an easy flowing polymer,high injection speeds can be achievedwith relatively low injection pressures. Aninjection speed up to 80% of themaximum speed will give good results.

Cooling phase

Holding pressure/holding time.For optimum appearance, quality anddimensional control, holding time playsan important role. In general the holdingtime of Stanyl is very short compared toother engineering plastics, since itsolidifies rapidly.Sink marks and voids caused byshrinkage can be reduced by applyingan adequate holding pressure. However,the holding pressure should not be sohigh that stresses are induced. Onemethod of determining the correct levelis by increasing the holding pressureuntil no sink marks are visible. Aftercompletely cooling down, thecomponent is then cut open at itsthickest section and inspected for voids.If necessary the holding pressure isincreased. Another method to determinethe holding time is to weigh thecomponents (without sprue) andincrease the holding time until a constantweight is achieved.A more sophisticated method is by usingpressure transducers in the cavity todetermine the exact moment of freeze-off. An example of a 3.2 mm UL barshows that Stanyl needs only half theholding time compared to PA66 (seeFigure 21). In combination with highermould ejection temperatures, thisexplains the very short cycle timescompared to other engineering plastics.

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Mould temperature and coolingtime. In addition to holding pressureand holding time, cooling time andmould temperature are also important.Because Stanyl solidifies rapidly, thecooling time is very short. For thisreason, the plasticizing time is thedetermining step the cycle time.In general, mould temperatures of 80 °Care recommended for good dimensionalstability and flow properties. To reducepost-shrinkage, increase toughness,improve the surface appearance orachieve maximum crystallinity mouldtemperatures may be increased up to120 °C and sometimes even higher,especially for Stanyl UF.In some specific cases a mouldtemperature lower than 80 °C hasadvantages. A practical example ismetallization, where an etched surfaceresults in a better adhesion of the metal.Furthermore, good cooling is necessaryto reduce warpage. For optimum coolingthe positioning of the cooling channels isvery important.

Mould ejection. Stanyl does not stickto the mould surface and has goodejection properties. Due to the highcrystallisation rate, the surface solidifiesvery fast and exhibits a high stiffness athigh temperatures, so that Stanyl can beejected at relatively high temperatures(Twall 200 °C) resulting in short cycletimes (20 - 30% faster than PA66).

Breaks during production

Take care that the nozzle does notfreeze off when production isinterrupted.

Figure 21. Determination ofgate freeze-off 5)

5) Test piece UL-bar 3.2 mm, injectiontemperature 270 (PA66)and 310 °C (PA46),mould temperature 80 °C, holding pressure 450 bar.

Injection system. TDI-Pump-Nozzle assembly used in the latestrange Turbo-Diesel-Injection engines of VW Passat/ Bora/Golf (4 cylinder) andLupo. Also in Audi A3/A4 and A6. The pump-nozzle cable-assembly iswater/oil proof and connects outside engine management with inside enginecylinder head injection pump system. Stanyl has been selected because of itsheat- and oil resistance (> 2000 hrs/150 °C).

This can cause a backward moving meltfront when production is started again.

Short breaks. When a break duringproduction is expected, the hoppershould be closed, the screw emptiedand the screw put into the forwardposition. The cylinder temperatures canbe maintained. When starting up, purgewith fresh material.

Production breaks of 1-2 hours.Empty the hopper (to prevent materialfrom absorbing moisture), empty thescrew, put the screw into the forwardposition and lower the cylindertemperatures to 260 °C.

When starting up, first purge with freshmaterial.For flame retardant grades always purgethe cylinder with HDPE.

Cleaning the injection unit

When production with Stanyl is finished,empty the hopper and the screw andpurge with a high melt viscosity grade ofHDPE (MFI 0.2) such as StamylanHD7625 (DSM). Lower the cylindertemperatures during purging to therequired level of the polymer to beprocessed.

Characteristics properties of Stanyl

General

Stanyl is a high performance polyamidewhich is used in demanding applicationsin the automotive andelectrical/electronics industry and inother applications where a combinationof high heat resistance, excellent flow,high mechanical properties oroutstanding wear and friction behaviouris required. Stanyl’s high number ofamide groups per given chain length andthe highly symmetrical chain structure(see also Introduction) result in a highmelting temperature (295 °C), a highcrystallinity and fast crystallization.Stanyl’s high crystallinity (approximately70%), results in a high heat distortiontemperature (190 °C for unreinforcedStanyl and 290 °C for glass fibrereinforced Stanyl), excellent creepbehaviour (especially at elevatedtemperatures), high oxidative stabilityand excellent abrasion resistance. Thehigh crystallization rate of Stanyl resultsin the formation of many smallspherulites. This explains the superiortoughness of Stanyl compared to otherengineering plastics, resulting in a uniquecombination of toughness and high heatresistance (see Figure 5 page 13 andFigure 22). The combination of highcrystallinity and many small spherulitesresults in excellent fatigue behaviour. Inaddition, the high crystallization rate ofStanyl enables faster cooling and thusshort cycle times.

Due to its unique combination ofexcellent mechanical properties and highheat resistance (see Figure 23), Stanylbridges the gap between conventionalengineering plastics such as PA6, PA66and polyesters and more exoticmaterials such as LCP, PPS, PSU, PEEKand PES, PEI.

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Figure 23. Tensile strength versus heat resistance of Stanyl and other engineering plastics.

Figure 22. Impact versus heat resistance of Stanyl and other engineering plastics.

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Stanyl’s high performance leads toimportant advantages for the customerincluding cost reduction, longer lifetimeand higher reliability due to:- excellent short-term and long-term

heat resistance- high stiffness at elevated temperatures - high creep resistance, especially at

elevated temperatures- outstanding toughness- excellent fatigue behaviour- superb wear and friction properties- excellent flow- good resistance to chemicals- high level of electrical properties

combined with V-0 UL flammabilitylistings for flame retardant grades

- high productivity due to short cycletimes and low reject levels

- no flash.

Temperature Performance.

The temperature performance of everyengineering plastic can be described by:- a peak temperature resistance or

short term temperature resistance, asindicated by the melting point, Vicat ora Heat Distortion Temperature and acertain level of stiffness and strengthat a certain elevated temperature

- a resistance to long-term exposure atelevated temperatures with or withouta load applied (with load: creepresistance, without load: Absolute RealOperating-value, see page 34).

Short Term Heat Performance

In today’s high tech world, theperformance of engineering plastics overa wide temperature range is often ofcritical importance. An indication of theshort term temperature performance of amaterial is its stiffness and strength atelevated temperatures (for instancebetween 100 °C and 280 °C).

Figure 24a. Shear modulus ofunreinforcedpolyamides.

Figure 24b. Shear modulus of30% (PPS 40%) glassfibre reinforcedengineering plastics.

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Table 10. Stiffness at various conditions and various GF reinforcements levels.

Polymer Stanyl PA66 PPS PPATmelt (ºC) 295 260 285 315Tg (ºC) 80 65 90 120HDT 1.8 MPa (ºC) 290 250 265 280E-Modulus (MPa) 30% GF 30% GF 30% GF 30% GF

reinforced reinforced reinforced reinforced23 ºC 10000 9500 11700 1280023 ºC/50% RH 6500 6500 11700 12800120 ºC 5500 4400 7200140 ºC 5300 4100 4000160 ºC 5000 3800 3600E-Modulus (MPa) 40% GF 40% GF 40% GF 40% GF

reinforced reinforced reinforced reinforced23 ºC 13000 12500 16300 1620023 ºC/50% RH 8000 8500 16300 16200120 ºC 6600 5600 7900 9000140 ºC 6300 5200 7100 5000160 ºC 6000 4800 6000 4400Tensile strength (MPa) 30% GF 30% GF 40% GF 30% GF

reinforced reinforced reinforced reinforced23 ºC 210 180 170 20023 ºC/50% RH 115 140 170 170120 ºC 105 85 95 100140 ºC 100 80 80 70160 ºC 90 65 65 60

This stiffness/strength level at elevatedtemperatures should be considered asthe critical level to design for, sincemeasurements at room temperature arein general much higher (even aftermoisture absorption).The shear modulus offers a way ofcomparing the stiffness ofthermoplastics at different temperatures.Due to its high level of crystallinity.Stanyl retains its stiffness to a greatextent at elevated temperatures closeto its melting point 295 °C (see Figures24a, b, c), which ensures a wider safetymargin for critical applications incomparison to competitive materialssuch as polyesters, PA6 and PA66 andPPAs. PPA and PPS have a very highmodulus at room temperature but showa significant drop in stiffness attemperatures above 100 °C (see Figure24b). In practice, Stanyl has the higheststiffness at temperatures higher than 120 °C, when compared to competitivematerials with the same level ofreinforcement.

The superior stiffness also allows Stanylto be used in applications exposed tohigh peak or high operatingtemperatures where otherthermoplastics fail (see connector andautomotive applications). By addingreinforcers, stiffness can be furtherincreased (see Figure 24c).

Other indicators of the stiffness, whichare more suitable as a design criterionthan the shear modulus, are the tensileand the flexural moduli; for polyamidesthese properties (and other mechanicalproperties like tensile or flexural strength)merely depend on ambienttemperatures, moisture content, heatexposure, the type and amount ofreinforcement or other additives(lubricants, pigments) used, see Table10. This table again shows Stanyl’ssuperior strength and stiffness atelevated temperatures compared tocompetitive high performancethermoplastics.

Figure 24c. Shear modulus of some Stanyl grades.

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Figure 25b. Creep modulus of glass fibre reinforced (30 or 33%) engineering plastics.

Figure 25a. Creep modulus of unreinforced polyamides. The melting point in combination withthe Heat Distortion Temperature (HDT)gives a good impression of the peaktemperature resistance under load. TheHDT is defined as the temperature atwhich a test bar is deformed to a givenextent at a given applied load; this isrelated to a certain level of stiffness atthe elevated temperature. Due to itsexcellent retention of stiffness at highertemperatures, the HDT-rating of Stanyl(190 °C for unreinforced and 290 °C for30% glass fibre reinforced grades) ishigher than that of other engineeringplastics (see Figure 23).

Long Term Heat Performance

Creep resistance. For optimumperformance and maximum lifetimes,engineering plastics which are subjectedto long-term loading must have a highcreep resistance (i.e. low plasticdeformation under load).

Stanyl’s high crystallinity results in anexcellent stiffness retention at elevatedtemperatures (above 100 ºC) and hencein creep resistance, which is superior tothat of most engineering plastics andheat-resistant materials (see Figure 25aand 25b).

Figure 25c shows the effect of glass fibrereinforcement on the creep modulus ofStanyl at 140 ºC. Creep behaviour couldbe one of the factors that limits themaximum application temperature of amaterial.

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Figure 25c. Creep modulus of some Stanyl grades (GF = glass fibre reinforced)Heat ageing in air

For designers it is crucial to know theperformance level of the end-productand therefore of the material at the endof its lifetime, which often means afterexposure for thousands of hours to heatin an oxygen containing environment.This performance (heat or air ageingresistance) can be expressed in variousways: different parameters like strength,stiffness, impact resistance, elongationat break (measured either at roomtemperature or at the elevatedtemperatures) can be selected tomonitor the performance after heatageing over time. The results of thesemeasurements can again be displayed invarious ways: in a relative way viaretention levels or via relativecharacteristics e.g. Continuous UseTemperature and Relative TemperatureIndex, or in an absolute way as in therecently introduced Absolute RealOperating (ARO) Value concept. Thisconcept shows the strength measuredat the absolute real operatingtemperature e.g. of 150 °C after ageingat 150 °C.

Figure 26. Continuous use temperatures of some Stanyl grades.

Diode carrier.

Figure 27. Absolute level oftensile strength at 23 °C after heatageing at 150 °Cfor Stanyl and competitivethermoplastics.

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Figure 28. CUT at 5000 hours for Stanyl and competitive materials.

* depending on the exact heat stabilizer package and content used.

The Continuous Use Temperature (CUT),frequently used in the automotiveindustry as a selection criterion, isdefined as the temperature at which agiven mechanical property (usuallytensile strength or impact resistance)measured at 23 °C decreases by 50%within a certain period of time (usually500, 1000, 5000, 10000 or 20000hours). From Figure 26 it follows that theCUT of 30% glass fibre reinforced StanylTW200F6 at 5000 hours is 170 °C (after5000 hours of ageing at 170 °C the dropin tensile strength is 50%). The differentCUTs for different ageing times are alsosummarized in Figure 26.

The Relative Temperature Index,frequently used in the E&E industry, asgiven by UL (see Table 7 ULrecognitions, chapter E&E) can beconsidered to a certain extent as a CUTfor very long half-life times rangingbetween 60000 and 100000 hours: theRTI of heat stabilized Stanyl 30% GF is140 °C.The recently introduced concept of theAbsolute Real Operating Value afterheat ageing, gives designers morerealistic comparisons between thevarious materials. It overcomes the majordrawbacks of the CUT- and RTI-concepts, namely that these conceptsonly consider the retention of propertiesand measure these poperties only atroom temperature, after heat ageing.

Certain materials which start at very lowlevels but retain this level to a highdegree (as for instance PPS, see Figure27 and 29) are rated better in CUT-termsthan other materials which start at ahigher level and show a strongerreduction. However, the last materialscan in absolute values still outperformthe former materials after the heatageing exposure. Additionally the CUT-concept is based on measurements ofproperties at room temperature, whilstthe more critical design levels are tobe expected in the elevatedtemperature range. The ARO conceptis demonstrated in Figures 29 and 30and Table 11, which show thesuperiority of Stanyl in comparison withPA66, PPA and PPS after heat ageing at150 °C and 170 °C.

Comparing Figures 28 and 30 clearlyshow how misleading CUT can be whenpositioning engineering plastics for theirheat ageing performance: the ARO valueresults in a much more realisticpositioning.

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Figure 29. Absolute level oftensile strength atreal operatingtemperature (150 °C) after heatageing at 150 °Cfor Stanyl andcompetitivethermoplastics.

Figure 30. Positioning ofthermoplasticsaccording to ARO-concept.

Locking spring of a mobile phone connector (Stanyl TW341).

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Toughness, fatigue and wearproperties. Whilst tensile and flexuralstrength decrease with increasingtemperature, toughness, as measuredby elongation at break and impactresistance, increases. Therefore thecritical factor is usually the toughnessperformance at lower temperatures. Dueto its fine crystalline structure,unreinforced Stanyl exhibitsextraordinary impact resistance incomparison with many other engineeringplastics (see Figure 22). Notched impactvalues remain at a high level even attemperatures below 0 ºC.

The effect of different amounts of glassfibre reinforcement is different for bothtoughness parameters. With increasingreinforcement percentages, theelongation at break decreases whilst thenotched impact resistance increases.

The notched Izod impact resistance ofglass fibre reinforced Stanyl isunmatched (see Figure 22).This makes Stanyl the material of choicefor demanding applications andfacilitates further assembly steps, forinstance using inserts and snap-fits.

Since this is combined with a very highelongation at break (see Figure 31),Stanyl offers the best solution for thin-walled parts, snap-fits, film hinges andinsert moulding of gears, pulleys and dipswitches.

Properties Stanyl PPA PA66

ARO 5000 hrsStrength at high temp. (MPa)after ageing at high temp.150 °C 110 90 70170 °C 90 80 50

CUT 5000 hrs (°C) 170 185 130-170*

E-modulus (MPa)150 °C 5200 4000 4000170 °C 4700 3500 3500

Table 11. Heat ageing resistance as expressed by the CUT and ARO-concept and stiffnessat elevated temperatures for Stanyl and competitive polyamides (30% GF reinforced).

* Depending on the exact heat stabilizer package and content used.

Figure 31. Tensile and temperaturebehaviour of 30%glass fibre reinforcedengineering plastics.

Hall sensor, Stanyl TW200F6.

The high crystallinity and fine crystallinestructure of Stanyl lead to a fatigueresistance superior to that of most otherengineering and heat resistant plastics,(see Figure 32). The fatigue resistance ofStanyl is much better than that of PPA,PPS and PA66. Fatigue resistance isparticulary important for gears and chaintensioners.

Stanyl also has excellent abrasion (orwear) resistance and outperforms manyother engineering plastics under mostconditions.Figure 33 shows a comparison betweenStanyl, PA66 and POM according to theTaber Abrasion test (ASTM D1044).Although the coefficients of friction ofstandard grades of these materials arequite similar, Stanyl outperforms itscompetitors. The main reason is itshigher pressure velocity (PV) rating,which permits higher pressures orvelocities to be used (see Figure 34).

Modified Stanyl grades with even betterwear properties, are available inunreinforced (e.g. TW371) as well as inglass fibre reinforced (e.g. TW271F6;30% GF) form. Its smooth and toughsurface, combined with its stiffness atelevated temperatures, makes Stanyl anideal material for sliding parts. Theseinclude valve lifter guides, chaintensioners, bearings and thrust washers.

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Figure 32. Fatigue resistanceat 140 °C of glassfibre reinforcedengineeringplastics.

Stanyl provides toughness for recycable oil filter housings, Stanyl TW200F6.

Figure 33. Taber abrasionresistance.

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Flow

One of Stanyl’s key features has alwaysbeen its excellent flow duringprocessing. This allows Stanyl to beused in its applications with very narrowwall sections, as in different types ofconnectors used in Information andCommunication Technology (ICT). Thiscombined with a high level of mechanicalproperties and short cycle times (lowerprocessing costs) has led the use ofStanyl in many applications such asmemory connectors, fine pitchconnectors, mobile phone and ZIF-PGAconnectors (see also chapter E&Eapplications). Trends in this market aretowards higher speeds and largeroutputs. This implies a further demandon increased flowability for thethermoplastic materials used. DSMEngineering Plastics has developed anew generation of Stanyl: the StanylHigh Flow series. The first commercialgrade in this series is a 40% glass fibrereinforced, flame retardant material:46HF5040. This material clearly has aneven higher flow than the standardStanyl types otherwise used for theseapplications (TE250F6, F8 and F9). It also outperforms many competitivematerials, even LCPs, which are knownfor their excellent flow.

This outstanding flow is combined withthe usual high level of mechanicalproperties (high modulus, hightoughness), high HDT and high meltingpoint of standard Stanyl grades, clearlycreating a product with a uniqueproperty-flow balance (see Figure 35).

Figure 34. PV Diagram.

Charge air-intercooler, Stanyl TW200F6.

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The high mechanical properties assuregood pin retention and low reject levelsduring pin insertion. Stanyl 46HF5040.The fast crystallization of Stanyl46HF5040, once again results in shortcycle times during injection moulding,offering a cost-effective solution for themost demanding applications.Stanyl 46HF5040 is less sensitive toshear heating and can be processed athigher melt temperatures.

Figure 35. Spiral flow versus tensile strength.

Increasing the melt temperature from305 °C (as used for standard flameretardant Stanyl grades) to 325 °Cresults in a further increase in flow (seeFigure 15) and an increase in mechanicalproperties. The lower sensitivity, to shearheating, requires that High Flow gradesbe processed differently from thestandard flame retardant Stanyl grades(see processing of Stanyl High Flowpage 28).

Table 12. Dimensional changeas a function ofmoisture uptake ofnon-flame-retardantgrades.

Dimensional change (%) Stanyl Stanyl PA66 PPA Stanylin flow/perp. to flow UF 30% GF 30% GF 30% GF 50% GF50% RH - oriented part 0.7/0.7 0.15/0.6-0.9 0.1/0.4 0.1/0.3-0.4 0.1/0.5-0.850% RH - not oriented 0.8/0.8 0.3/0.6-0.9 0.15/0.4 0.15/0.3-0.4 0.3/0.3-0.6

90% RH - oriented part 1.8/1.9 0.35/1.4 0.2/1.0 0.2/0.5 0.2/1.290% RH - not oriented 2.2/2.2 0.5/1.5 0.4/0.9 0.2/0.3 0.8/0.8

Stanyl 46HF5040 is already used in thenew generation of memory connectors(DDR-DIMM, RIMM) and ZIF-PGA andZIF-BGA sockets. The outstanding flowresults in lower injection pressuresduring injection moulding, a lower levelof built-in-stresses and consequently,lower warpage.

Stanyl 46HF5040 has a V-0 UL-94 listingat 0.8 mm. This grade is the first one inthe new High Flow series.

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Water absorption and hydrolysisresistance

Like all polyamides, Stanyl reversiblyabsorbs moisture from the environmentuntil it reaches an equilibrium (see Figure36). Although Stanyl absorbs moremoisture than PA66, the resultingdimensional change at equilibrium is of asimilar order (see Figure 10 ChapterProcessing). This can be explained bythe higher crystallinity level of Stanyl.

When dealing with applications with verytight tolerances with respect todimensions, the use of polyamides is notrecommended. Note however that formany applications (even for connectorswith very narrow tolerances, see chapterE&E applications) the dimensionalstability of Stanyl matches thesestringent specifications (see Table 12).

At room temperature, moistureabsorption will lower stiffness andstrength while increasing toughness. Attemperatures above 80 ºC (the glasstransition temperature of Stanyl) theeffect of moisture absorption on Stanyl’sstiffness is negligible (see Figure 37).In the case of materials like PA66 andPPA the effect of moisture absorption ismore pronounced. Their stiffness dropsmore sharply at elevated temperaturesdue to their lower crystallinity whencompared to Stanyl.

Figure 37. Influence of moistureuptake on shearmodulus of glassfibre reinforcedpolyamides.

Figure 36. Water absorption 23 °C in air 65% RH.

Fasteners.

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In the case of conditioned PPA, the dropin stiffness already takes place around100 ºC. This means that in practice thestiffness and creep of Stanyl is superiorto that of PPA at temperatures above100 ºC.

Chemical Resistance. Polyamidesare well known for their resistance to awide range of chemicals. Stanyl is noexception.

Its resistance to oils and greases isexcellent especially at highertemperatures (see Figures 38 and 39).Stanyl is therefore an ideal material forunder-the-bonnet applications in theautomotive industry and for otherindustrial applications such as gears andbearings.

Liker all other polyamides, Stanyl isattacked by strong mineral acids andabsorbs polar solvents. Informationconcerning the resistance of Stanyl tovarious chemicals and solvents isavailable on request from your local DSMsales office.

Figure 38. Influence of immersion in oil* on flexural strength of 30% glass fibre reinforcedpolyamides.

Figure 39. Retention ofmechanicalproperties (of 30%glass fibrereinforcedpolyamides) after1000 hoursimmersion in oil*.

SMD-resistant DIN connectors.

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Electrical properties,flammability and ULclassifications

Stanyl exhibits high levels of surface andvolume resistivity, dielectric strength andcomparative tracking resistance. Theexact levels of these properties dependon the specific grade, temperature andmoisture content. In general theseproperties are sufficiently retained at elevated temperatures to fulfil criticalapplicational requirements. This fact, incombination with its very high peaktemperature resistance and its hightoughness level, makes Stanyl anexcellent choice for components whichhave to be soldered onto printed-circuitboards (PCB’s).

A number of flame retardant grades havebeen developed and are rated V-0according to the UnderwritersLaboratories UL 94 classification (someeven at 0.35 mm).

The unmodified, unreinforced Stanylgrades are rated V-2 and the glass fibrereinforced grades without flameretardant are rated HB.

Other classifications according to anumber of UL standards have beenobtained for different Stanyl grades. InTable 6 and 7 the most important ratingsaccording to UL have been summarized.The class H (180 ºC) rating according toUL 1446 for Stanyl glass fibre reinforcedgrades is worth noting.

A complete overview of the total systemrating is also available at your local DSMsales office or at UL’s websitehttp://data.ul.com

After-treatments

Plastic parts are often subjected to afinishing operation after the actualmoulding step. This can be a functionaloperation such as machining, glueing,welding, screwing or snap-fitting, or adecorative treatment, such as vacuummetallization, electroplating, lacquering,printing or laser marking.

Although Stanyl is generally used in partswhich primarily have to fufil highlytechnical requirements, decorativefinishing techniques are sometimesapplied for reasons of productidentification (laser marking) orfunctionality (metallization). The samecoating systems and techniques whichare used for PA66 are applicable toStanyl.

With regard to these after-treatmentsStanyl will show a better adhesionbehaviour, due to its higher polarity,when the finishing technique is appliedto “dry-as-moulded” parts.

Since high-temperature-resistant gluesare not available, welding and snap-fitting are the preferred bondingtechniques for Stanyl. Welding should beperformed on “dry-as-moulded” parts inorder to achieve maximum weldstrengths.

More detailed information can beobtained through your local DSM salesoffice.

View at the lower part of the Stanyl reactor.

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DSM Engineering Plastics product portfolio

Stanyl® PA46 High temperature polyamide which bridges the price-performance gap between 46 polyamide traditional polyamides and high-performance materials.

Stanyl® PA46 An innovative PA46 which combines excellent mechanical performance High Flow™ with (LCP-like) high flow and low warpage resulting in cost-savings for demanding high-end46 polyamide applications.

Akulon® Polyamide 6 and 66 in both unreinforced and reinforced grades, including flame retardant products.polyamides

Akulon® Ultraflow™ Polyamide 6 reinforced grades, easy flowing, lower processing temperatures,polyamide faster crystallization speed, shorter injection and holding time, reduced cycle time.

Arnite® PBT and PET based materials, including unreinforced, reinforced, and flame retardant grades,thermoplastic polyester offering excellent dimensional stability and low creep with good chemical resistance.

Arnitel® High performance elastomers based on polyester.copolyester elastomers

Stamylan® UH A high performance polymer having outstanding abrasion resistance in combination with excellentultra high molecular impact and chemical resistance, low coefficient of friction and very good electric and dielectricweight polyethylene properties.

Stapron® Unreinforced and reinforced PC-blends. Flame retardant grades based on halogen free systems.PC/ABS-blendPC/PET-blend

Xantar® Unreinforced, reinforced, and flame retardant grades with outstanding impact resistance, polycarbonate dimensional stability, and high heat deflection temperature.

Xantar® C A new generation PC/ABS-blend providing improved flow, simultaneously increasing PC/ABS-blend impact and stress-crack resistance, while optical appearance and stability are on a very high

and consistent level.

Yparex® This family of extrudable adhesive resins consists of polyolefins with incorporated functional groups,adhesive resin which provide the necessary bond between polyolefins and polar materials (e.g. PA, EVOH, glass) or

metals (e.g. steel, aluminium, brass, copper).

® Registered tradenames of DSM

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