Brochura PCP Ticona

Vectra®

liquid crystal polymer (LCP)

• high melt flow• easily fills long, thin

complicated flow paths with minimal warpage

• excellent dimensional stability

• inherently flame retardant

• heat deflection up to 300°C

• excellent organic solvent resistance

• fast cycling, wide processing window

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Vectra®

Liquid crystal polymers (LCP)

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Vectra®


Table of Contents

1. Introduction and overview

2. Vectra LCP Product Line

2.1. Grade description2.1.1 Glass fibre reinforced grades (100-series)2.1.2 Carbon fibre reinforced grades (200-series)2.1.3 Mineral filled grades (500-series)2.1.4 Graphite filled grades (600-series)2.1.5 Filler/fiber combinations (400-series)2.1.6 Speciality grades (700 and 800-series)2.2. Colors2.3. Packaging

3. Physical properties

3.1. Mechanical3.1.1. Anisotropy and wall thickness 3.1.2. Short term stress3.1.3. Behavior under long term stress 3.1.4. Notch sensitivity (Impact testing) 3.1.5. Fatigue 3.1.6. Tribological properties 3.1.7. Damping 3.2. Thermal properties3.2.1. Dynamic mechanical spectra3.2.2. Deflection temperature under load3.2.3. Coefficient of linear thermal expansion 3.2.4. Soldering compatibility3.2.5. Thermodynamics, phase transition 3.3. Flammability and combustion3.4. Electrical properties3.5. Regulatory approvals3.5.1. Military specification3.5.2. Food and Drug Administration3.5.3. United State Pharmacopoeia3.5.4. Biological Evaluation of Medical Devices

(ISO 10993)3.5.5. Underwriters Laboratories3.5.6. Canadian Standards Association3.5.7 Water Approvals – Germany and Great Britain

4. Environmental effects

4.1. Hydrolysis4.2. Chemicals and solvents 4.3. Permeability4.4. Radiation4.5. Ultraviolet and weathering resistance

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5. Processing

5.1. Safety considerations5.1.1. Startup and shutdown procedures5.1.2. Fire precautions5.2. Drying and storage

6. Injection Molding

6.1. Equipment selection6.1.1. General6.1.2. Screw design6.1.3. Check ring 6.1.4. Nozzle6.1.5. Hot runner systems6.2. Injection molding processing conditions6.2.1. Melt temperature6.2.2. Injection velocity6.2.3. Mold temperature6.2.4. Screw speed6.2.5. Backpressure6.2.6. Screw decompression6.2.7. Injection pressure6.2.8. Holding pressure6.2.9. Cycle time6.3. Regrind 6.3.1. General recommendations6.3.2. Equipment6.3.3. Using regrind6.4. Troubleshooting6.4.1. Brittleness6.4.2. Burn marks6.4.3. Dimensional variability6.4.4. Discoloration6.4.5. Flashing6.4.6. Jetting6.4.7. Leaking check ring6.4.8. Nozzle problems6.4.9. Short shots6.4.10. Sinks and voids6.4.11. Sticking6.4.12. Surface marks and blisters6.4.13. Warpage and part distortion6.4.14. Weld lines

7. Extrusion

7.1. Equipment selection7.1.1. General7.1.2. Screw design

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Introductionand Overview

Vectra LCPProduct Line

Physical properties

Environmentaleffects

Processing

Injection Molding

Extrusion

Rheology

Design

Annealing

Finishingand Assembly

ConversionTables

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7.1.3. Screen pack7.1.4. Head and die7.1.5. Melt pump7.2. Processing7.2.1. Film and sheet7.2.2. Profile7.2.3. Pipe and tubing7.2.4. Overcoating7.3. Troubleshooting7.3.1. Extrudate cross section varies with time7.3.2. Extrudate has excessive voids7.3.3. Poor surface appearance7.3.4. Striations on extrudate in machine direction7.3.5. Bowing of pipe or tubing7.3.6. Poor surface only on inner wall7.3.7. Wall thickness variation7.3.8. Extrudate has distorted cross section7.3.9. Strands break in extrudate7.3.10. Large, uniformly spaced perforations in film7.3.11. Sagging extrudate7.3.12. Uneven or distorted edges7.3.13. Breaks in optical fiber7.3.14. Out of round cross section

8. Rheology

9. Design

9.1. Part design9.1.1. Nominal wall thickness9.1.2. Flow length and wall thickness9.1.3. Shrinkage9.1.4. Draft angle 9.1.5. Warp9.1.6. Knit lines9.1.7. Ribs, corners, radii9.1.8. Holes and depressions9.1.9. Latches, snap fits, interference fits9.2. Mold design9.2.1. Mold material9.2.2. Finish9.2.3. Runner systems9.2.4. Gate location9.2.5. Gate size9.2.6. Gate design9.2.6.1. Submarine (tunnel) gates 9.2.6.2. Pin gates9.2.6.3. Edge gates9.2.6.4. Film (fan) gates9.2.6.5. Ring and diaphragm gates9.2.6.6. Overflow gates9.2.7. Vents9.2.8. Ejection9.2.8.1. Sprue puller

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10. Annealing

11. Finishing and Assembly

11.1. Welding11.1.1. Ultrasonic welding 11.1.2. Rotational (spin) welding11.1.3. Hot plate welding11.1.4. Vibration welding11.1.5. Hot and cold staking 11.1.6. Electromagnetic welding11.2. Adhesive Bonding11.2.1. Surface preparation 11.3. Fasteners11.3.1. Screws 11.3.2. Ultrasonic inserts11.4. Decoration11.4.1. Printing11.4.2. Painting 11.4.3. Laser marking11.5. Metallization and Molded Interconnect

Devices (MID) 11.6. Machining11.6.1. Prototype machining11.6.2. Tooling11.6.3. Turning11.6.4. Milling and drilling11.6.5. Threading and tapping11.6.6. Sawing

12. Conversion Tables

12.1.1. Unit conversion factors12.1.2. Tensile or flexural property conversion12.1.3. Length conversion12.1.4. Temperature conversion

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Physical properties


Processing

Injection Molding

Extrusion

Rheology

Design

Annealing


ConversionTables

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List of TablesTable 1.1 Comparison of amorphous, semi-

crystalline and liquid crystalline polymers

Table 1.2 Key performance characteristics by market

Table 2.1 Available color master batches Table 3.0 Short-term properties of Vectra® LCP Table 3.1.1 Anisotropy of properties – 2mm thick Table 3.1.2 Anisotropy of properties – 1mm thick Table 3.1.3 Coefficient of friction, µ,

of Vectra® LCP Table 3.2.1 Dynamic mechanical analysis Table 3.2.2 Typical CLTE values of Vectra® LCP

vs. other engineering plastics Table 3.2.3 Coefficient of Linear Expansion

(-50 to 200°C) Table 3.2.4 Vapor phase soldering stability

of Vectra® LCPTable 3.2.5 Soldering compatibility of Vectra® LCPTable 3.3.1 Smoke density of Vectra A950 Table 3.3.2 Products of combustion of Vectra A950 Table 3.3.3 Heat release of Vectra A950 Table 3.3.4 Underwriters Laboratories listing for

Vectra® LCP Table 3.4.1 Vectra® LCP conductive grades Table 3.4.2 Relative permittivity

(Dielectric constant) Table 3.4.3 Dielectric loss tangent

(Dissipation factor) Table 4.2.1 Chemical resistance Table 4.3.1 Oxygen permeability Table 4.3.2 Water vapor transmission Table 4.4.1 Cobalt 60 radiation Table 4.5.1 Results of artificial weathering

for 2,000 hours Table 7.0 Vectra® LCP grades suitable for

extrusion Table 9.1 Shrinkage measurementsTable 9.2 Partial Listing of Potential Mold SteelsTable 11.1.1 Electromagnetic welding strengths Table 11.2.1 Lap shear strength Table 11.2.2 Typical Adhesives for Vectra® LCP Table 11.2.3 Adhesives compliant with

US RegulationsTable 11.2.4 Lap shear strengths Table 11.3.1 Typical screw dimensions Table 11.3.2 Ejot PT® K screwTable 11.3.3 Performance of molded-in insertsTable 11.6.1 Tool speeds for drilling or milling

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Physical properties


Processing

Injection Molding

Extrusion

Rheology

Design

Annealing


ConversionTables

List of FiguresFig. 1.1 Representation of the structural

differences between liquid crystalpolymers and conventional semi-crystalline polymers

Fig. 1.2 Price performance comparison ofvarious plastic resins

Fig. 2.1 Vectra® LCP product lineFig. 3.0 Fracture surface of Vectra® LCP Fig. 3.1.1 Comparison of anisotropy of Vectra®

LCP versus Celanex® PBT Fig. 3.1.2 Micrograph of orientation in outer

layers Fig. 3.1.3 Tensile modulus versus wall thickness Fig. 3.1.4 Tensile strength versus wall thicknessFig. 3.1.5 Flex modulus versus wall thickness Fig. 3.1.6 Flex strength versus wall thicknessFig. 3.1.7 Stress strain curves at 23°CFig. 3.1.8 a) Influence of temperature on the stress

strain behavior, Vectra B230 b) Influence of temperature on the stress strain behavior, Vectra E130i

Fig. 3.1.9 Tensile modulus versus temperature Fig. 3.1.10 Tensile strength versus temperature Fig. 3.1.11 Tensile creep modulus, Vectra E130i Fig. 3.1.12 Tensile creep modulus, Vectra H140 Fig. 3.1.13 Flexural creep modulus, Vectra A130 Fig. 3.1.14 Flexural creep modulus, Vectra B130 Fig. 3.1.15 Flexural creep modulus, Vectra C130 Fig. 3.1.16 Stress ranges in fatigue testing testsFig. 3.1.17 Wöhler curves for Vectra A130 (a),

Vectra B230 (b) and Vectra A530 (c),longitudinal direction determined in thealternating flexural stress range

Fig. 3.1.18 Friction and wear data Fig. 3.1.19 Damping properties Fig. 3.1.20 Vibration characteristicsFig. 3.2.1 Dynamic Mechanical Analysis,

Vectra A130 Fig. 3.2.2 Dynamic Mechanical Analysis,

Vectra A530 Fig. 3.2.3 Dynamic Mechanical Analysis,

Vectra B130 Fig. 3.2.4 Dynamic Mechanical Analysis,

Vectra B230 Fig. 3.2.5 Dynamic Mechanical Analysis,

Vectra E130iFig. 3.2.6 Dynamic Mechanical Analysis,

Vectra E530iFig. 3.2.7 Dynamic Mechanical Analysis,

Vectra H140

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Fig. 3.2.8 Dynamic Mechanical Analysis,Vectra L130

Fig. 3.2.9 Coefficients of Linear ThermalExpansion of selected engineering materials

Fig. 3.2.10 Sample geometry for CLTEmeasurements

Fig. 3.2.11 Specific heatFig. 3.2.12 Phase transition energy Fig. 3.2.13 Enthalpy Fig. 3.2.14 Thermal conductivity Fig. 3.4.1 Relative permittivity (dielectric

constant) for Vectra C130 Fig. 3.4.2 Dielectric loss tangent (dissipation

factor) for Vectra C130 Fig. 4.1.1 Tensile strength versus immersion time

in hot waterFig. 4.1.2 Tensile modulus versus immersion time

in hot water Fig. 4.1.3 Tensile strength versus immersion time

in steam Fig. 4.1.4 Tensile modulus versus immersion time

in steamFig. 4.3.1 Permeability of polymer filmsFig. 6.1.1 Metering type screws recommended

for processing Vectra® LCP Fig. 6.1.2 Check Ring non-return valve used on

injection molding machine Fig. 6.1.3 Hot runner systemFig. 6.1.4 Hot runner distributor Fig. 6.2.1 Typical injection molding conditions Fig. 8.1 Melt viscosity comparison, Vectra® LCP

versus semi crystalline polymer Fig. 8.2 Melt viscosity versus temperature

(filled) Fig. 8.3 Melt viscosity versus temperature

(unfilled) Fig. 9.1.1 Spiral flow lengths Fig. 9.1.2 Knit linesFig. 9.2.1 Typical Runner design for Vectra® LCP Fig. 9.2.2 Submarine gate Fig. 9.2.3 Sprue puller Fig. 11.1.1 Ultrasonic welding joint design Fig. 11.1.2 Ultrasonic weld strengthsFig. 11.1.3 Spin welding joint designFig. 11.1.4 Spin weld strengths for Vectra® LCP Fig. 11.1.5 Vibration welding Fig. 11.1.6 Electromagnetic welding Fig. 11.3.1 Boss for EJOT PT® K screw

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1. Introduction and Overview

Liquid crystal polymers (LCP) are a family of highperformance plastics, distinguished from other semi-crystalline resins by their long, rigid, rod-likemolecules that are ordered even in the melt phase(Fig. 1.1).

Vectra LCP is a family of high performance resinsbased on patented Ticona technology. The family iscomposed of a number of different base polymers.LCPs can be viewed in much the same context asother resin families, such as nylons. That is, whilebelonging to a common family, individual LCPs may have widely disparate processing characteristics,performance and applications.

The unique melting behavior of LCP has such a profound effect on properties and processing that we treat LCP as a separate category of polymers(Table 1.1). Even so, they can be processed with all of the techniques common to more conventionalthermoplastics including injection molding, extrusion,coextrusion, blow molding, etc.

Semi Crystalline Polymer

Lamellar Structure• Low Chain Continuity• Good Mechanical Properties

Random Coil

SolidState

Melt

Liquid Crystal Polymer

Extended Chain Structure• High Chain Continuity• Highest Mechanical Properties

Nematic Structure

Fig. 1.1 · Representation of Structural Differences between Liquid Crystal Polymers and

Conventional Semi Crystalline Polymers

Table 1.1· Comparison of Amorphous, Semi Crystalline, and Liquid Crystal Polymers

Amorphous Polymers

No sharp melting point/soften gradually

Random chain orientation in both solid andmelt phase

Do not flow as easily as semi-crystalline polymers in molding process

Fiberglass and/or mineral reinforcement onlyslightly improves Deflection Temperature underLoad (DTUL)

Can give a transparent part

Examples: cyclic olefinic copolymer (Topas®

COC), acrylonitrile-butadiene-styrene(ABS), polystyrene (PS), polycarbonate (PC), polysulfone (PSu), and polyetherimide (PEI)

Liquid Crystal Polymers

Melt over a range of temperatures; low heat of fusion

High chain continuity; extremely ordered molecular structure in both melt phase andsolid phase

Flow extremely well under shear within melting range

Reinforcement reduces anisotropy and increases load bearing capability and DTUL

Part is always opaque due to the crystal structure of liquid crystal resin

Examples: Vectra® LCP

Semi Crystalline Polymers

Relatively sharp melting point

Ordered arrangement of chains of moleculesand regular recurrence of crystalline structureonly in solid phase

Flow easily above melting point

Reinforcement increases load bearingcapabilities and DTUL considerably, particularlywith highly crystalline polymers

Part is usually opaque due to the crystalstructure of semi-crystalline resin

Examples: polyester (Impet® PET, Celanex® PBT,Duranex™ PBT), polyphenylene sulfide (Fortron® PPS),polyamide (Celanese® nylon), polyacetal copolymer (Celcon® POM,Hostaform® POM, Duracon™ POM)

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Vectra LCP offers a balance of properties unmatchedby most other resins. They are generally selected for aspecific application or market sector based on a fewkey characteristics such as those shown in Table 1.2below. For instance, in molding electrical connectors,high flow in thin walls, dimensional stability at hightemperatures and inherent flame retardance are thekey reasons for choosing an LCP. Key properties,such as high flow, stiffness and resistance to sterilizingradiation and sterilizing gases may make themcandidates for surgical instruments. A number ofVectra LCP grades are USP Class VI compliant andmeet ISO 10993 standards.

Vectra LCP can be processed into thin films and multi-layer articles by conventional means, althoughsome process development may be required. Film,sheet and laminates produced from Vectra LCPexhibit excellent dimensional stability and exceptionalbarrier properties. These superior barrier properties ofVectra LCP allow for much thinner barrier layers toachieve the same or better barrier performance thanlayers made of ethyl vinyl alcohol (EVOH) orpolyvinylidene chloride (PVDC). A wide range ofmarket segments, i.e., food, beverage, medical, indus-trial, and electronics utilize LCP. Many of theapplications benefit from the not only barrierproperties of LCP but also from low coefficient ofthermal expansion (CTE), chemical resistance, highstiffness, and strength.

The family of Vectra LCP resins is very easy toprocess in injection molding machines, which means

short cycle times, high flow in thin sections andexceptional repeatability of dimensions. Molded parts exhibit very low warp and shrinkage along withhigh dimensional stability, even when heated up to200-250°C.

New Vectra LCP compositions combine the consis-tency, stability, dimensional precision, and barrierproperties of traditional wholly aromatic LCPs withprocessability at lower temperatures ranging from220°C to 280°C. The combination of properties ofthese new compositions makes them suitable for usein moldings or laminates, and in blends with poly-olefins, polycarbonate, and polyesters.

The high strength-to-weight ratio of Vectra LCPmakes the resins exceptional candidates for metalreplacement applications. The maker of a needlelessmedical syringe estimated injection molded LCPcomponents were 75% lighter and 50% less costlythan machined metal parts. Compared with less costlyresins, easy-flowing Vectra LCP cut molding cyclesand many secondary operations to reduce the cost perpart. In addition, many Vectra LCP compositions arelisted by UL to allow the use of 50% regrind withoutloss of properties, enabling processors to improve costcompetitiveness even further. Although per pound orkilogram they can appear expensive, on a priceperformance continuum, Vectra LCP is cost effective(Figure 1.2). For many applications exposed to highservice stresses, Vectra LCP is the preferred alternativeto light metal alloys, thermosets and many otherthermoplastics.

E/E InterconnectsGood flow in thin wallsDimensional precisionHeat resistanceFlame retardance

HealthcareGood flow in thin wallsChemical resistanceWithstands sterilizationStiffness, strength

TelecommunicationsGood flow in thin wallsDimensional precisionStiffness, strength

AutomotiveGood flow in thin wallsSolvent resistanceTemperature resistanceDimensional stability

Business machinesGood flow in thin wallsDimensional precisionChemical resistance

PackagingExcellent barrier propertiesStiffness, strength

CryogenicsExcellent barrier propertiesGood low temperature propertiesStiffness, strength

Audio/VisualGood flow in thin wallsStiffness, strengthDimensional precisionTemperature resistance

Table 1.2 · Key performance characteristics by market

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POMCelconDuraconHostaformKemetal

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PA 6, 6Celanese

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Fig. 1.2 · Price Performance Comparison of Engineering and High Performance Plastics*

* High Performance Plastics Acronyms

ABS = acrylonitrile-butadiene-styrene HTN = high temperature polyamide (nylon)FP = fluoropolymers LCP = liquid crystal polymerPA6 = polyamide (nylon) 6 PA6,6 = polyamide (nylon) 6,6PA4,6 = polyamide (nylon) 4,6 PAS = polyaryl sulfonePBT = polybutylene terephthalate PCT = polycyclohexylenedimethylene terephthalatePEEK = polyether ether ketone PEI = polyether imidePES = polyether sulfone PET = polyethylene terephthalatePOM = polyoxymethylene (polyacetal) MPPO = modified polyphenylene oxideMFPPS = polyphenylene sulfide (mineral filled) GFPPS = polyphenylene sulfide (glass filled)PPA = polyphthalamide PSu = polysulfoneSPS = syndiotactic polystyrene PC = polycarbonate

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2. Vectra LCP Product Line

The Vectra LCP product line is built around a number of base polymers of varying compositions.The base polymers differ in their high temperatureperformance, rigidity, toughness and flowcharacteristics. Ticona is continuously developing newpolymers to tailor the composition to a specific need.

Each of these compositions can be used withoutmodification for extrusion or injection moldingapplications. Care should be taken when usingunfilled polymers for injection molding sincefibrillation of the oriented surface can occur. In addition, the base polymers can be compoundedwith various fillers and reinforcements to provide the necessary balance of thermal, mechanical,tribological or environmental properties for thespecific application or market need.

Figure 2.1 explains the product nomenclature andsurveys the Vectra LCP grades currently available.

2.1 Grade Descriptions

2.1.1 Glass fiber reinforced grades (100-series)

Reinforcement with glass fibers increases rigidity,mechanical strength and heat resistance. At the sametime the degree of anisotropy is reduced. Vectra LCPis available with 15%, 30%, 40% or 50% glass fiber.Examples: Vectra E130i (30% glass fiber), Vectra A130(30% glass fiber), Vectra B130 (30% glass fiber),Vectra C150 (50% glass fiber), Vectra L140 (40% glass fiber), etc.

2.1.2 Carbon fiber reinforced grades (200-series)

Reinforcement with carbon fibers gives higher rigiditythan with glass fibers. At the same time, the carbonfiber reinforced compositions have a lower densitythan the glass fiber grades with the same filler content.Carbon fiber reinforced polymers are used where thehighest possible stiffness is required. Note also thatcarbon fiber reinforced grades are conductive.Examples: Vectra A230 (30% carbon fiber), VectraB230 (30% carbon fiber)

2.1.3 Mineral filled grades (500-series)

The mineral filled grades typically have high impactstrength relative to the glass fiber reinforced grades.They have good flow and a good surface finish.Selected Vectra LCP polymers are available with 15%,30%, 40% or 50% mineral.Examples: Vectra A515 (15% mineral), Vectra E530i(30% mineral), Vectra A540 (40% mineral), VectraC550 (50% mineral)

2.1.4 Graphite filled grades (600-series)

Graphite flake provides some added lubricity andexceptionally good hydrolytic stability and chemicalresistance.Example: Vectra A625 (25% graphite flake)

2.1.5 Filler/fiber combinations (400-series)

Products with various filler and fiber combinationscomprise the 400-series. The PTFE and graphitemodified grades are used for bearing and wear resis-tant applications. The titanium dioxide modified gradehas high light reflectance.Examples: Vectra A420 (glass fiber, mineral, graphiteflake), Vectra A422 (glass fiber, graphite flake), VectraA430 (PTFE), Vectra A435 (glass fiber, PTFE), VectraC400 (glass fiber, TiO2)

2.1.6 Specialty grades (700 and 800-series)

The grades in the 700 series are modified with anelectrically conductive carbon black and suitable forelectrostatic dissipation.Examples: Vectra A700 (glass fiber, conductive carbonblack), Vectra A725 (graphite flake, PTFE, conductivecarbon black)The 800 series are grades developed especially forelectroless plating, EMI/RFI shielding, printed circuit boards and MID-components with integratedcircuits.Examples: Vectra C810 (glass, mineral), Vectra C820(mineral), and Vectra E820i (mineral)

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Fig. 2.1 · Vectra LCP Product Line

Unreinforced Polymer A950 B950 C950 D950 E950i H950 L950 LCP/PPS LKX1112

Glass fiber reinforced A115 C115 L115A130 B130 C130 D130M E130i H130 L130

H140 L140 V140A150 B150 C150

Carbon fiber reinforced A230 B230

PTFE modified A430A435

Mixed filler/fiber A410A420 C400A422

Mineral modified A515 E530iA530 C550A540

Graphite flake A625

Conductive (ESD) grades A700A725

Metallization (e.g. MID) C810 E820iC820 E820iPd

H-Polymer - Highest temperature capability

L-Polymer - Good value, balanced properties

V-Series - PPS/LCP alloy

LKX1112 - Low melt temperature for extrusion

A-Polymer - Industry Standard

B-Polymer - Highest stiffness

C-Polymer - Standard polymer, higher flow

D-Polymer - Encapsulated grade

E(i)-Polymer - Easiest flow, high temperature

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2.2 Colors

The natural color of Vectra LCP is ivory or beige.Graphite, carbon black and carbon fiber filled gradesare correspondingly black or anthracite in color.Vectra LCP can be colored in order to identify or differentiate between components. However, VectraLCP does not lend itself to “color matching”.

Color master batches (or concentrates) with a highpigment loading are available in a wide array of colors(Table 2.1). These master batches are supplied aspellets and are used for melt coloring of natural VectraLCP grades during processing.

Color master batches are available in both “A” and“Ei” polymer bases and all are cadmium free.

The last two digits at the end of the master batch codedenote the recommended mix ratio of natural pelletsto color master batch, e.g.:VJ3009K10 = 10:1VA3031K20 = 20:1

Lower concentrations are possible if the color effectachieved is satisfactory. Higher concentrations ofmaster batch are not recommended because of apotential decrease in mechanical properties or flow at higher loading.

2.3 Packaging

Vectra LCP is supplied as natural pellets about 3mm in size. Smaller pellets are available for VectraE130i only.

The standard package is a 25 kg bag although boxesand gaylords are available under some circumstances.

A9500 E9500I A9500/E9500i

Stock number Stock number Color number Standard Letdown Color

VC0006 VC0019 VD3003K20 20:1 Black

VC0010 VC0027 VA3031K20 20:1 White

VC0018 NA VE3047K10 10:1 Plum

VC0004 VC0030 VG3010K20 20:1 Blue

VC0003 VC0029 VJ3009K10 10:1 Mint green

VC0016 VC0031 VJ3040K10 10:1 Emerald green

VC0009 VC0028 VL3021K10 10:1 Yellow

VC0008 VC0032 VS3033K10 10:1 Fuchsia

VC0011 VC0026 VS3035K10 10:1 Red

VC0005 VC0033 VY3032K10 10:1 Brown

Table 2.1 · Available color master batches

NA = Not Available

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Vectra LCP belongs to the Ticona family of highperformance engineering resins. It is a rigid, toughmaterial with excellent heat resistance. Table 3.0summarizes short-term properties for the majority ofcommercially available Vectra LCP grades. Pleasecheck with your local Vectra LCP representative foravailability of additional grades.

Properties given in Table 3.0, measured on standardinjection molded test specimens, are typical values andcan be used for grade comparison. Their applicabilityto finished parts is limited because the strength of acomponent depends to a large extent on its design.

The level of properties depends on the type of filler orreinforcement used. Glass fibers impart increasedstiffness, tensile strength and heat deflectiontemperature. Carbon fibers give the highest stiffness.The addition of mineral fillers improves stiffness and provides increased toughness and a smoother surfacecompared to glass reinforced. Graphite flake improveselongation at break and provides added lubricity.PTFE modified grades have excellent sliding and wearproperties. The impact strength of unfilled VectraLCP is reduced by the addition of fillers andreinforcements, but is still relatively high.

3. Physical properties

The properties of Vectra® LCP are influenced to ahigh degree by its liquid crystal structure. The rodshaped molecules are oriented in the flow directionduring injection molding or extrusion. Due to thehighly ordered nature of LCP, the mechanicalproperties, shrinkage and other part characteristicsdepend upon the flow pattern in the part. Duringmold filling, the “fountain flow” effect causes themolecules on the surface to be stretched in the flowdirection. Ultimately, these molecules are located onthe surface of the part, which results in a skin that ishighly oriented in the flow direction (15-30% of thepart’s total thickness) (Figure 3.0). This molecularorientation causes a self-reinforcement effect givingexceptional flexural strength and modulus as well asgood tensile performance. For example, a commonlyused, 30% glass reinforced LCP, Vectra A130, hasstrength and stiffness about 50% higher than that ofcomparable 30% glass reinforced engineering resins.

Fig. 3.0 · Fracture surface of Vectra LCP

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Property Method Units LKX1112 A950 A115 A130 A150 B130

Physical

Density ISO 1183 kg/m3 1,400 1,500 1,620 1,790 1,600

Water Absorption ISO 62 % 0.005 0.009

Mechanical @ 23°C

Tensile Strength ISO 527 MPa 140 156 200 190 160 205

Tensile Modulus ISO 527 MPa 11,500 10,400 12,000 15,000 22,000 22,000

Elongation at Break ISO 527 % 2.0 2.6 3.1 2.1 1.1 1.0

Flexural Strength ISO 178 MPa 160 146 240 280 250 300

Flexural Modulus ISO 178 MPa 9,800 7,400 12,000 15,000 21,000 20,000

Compressive Strength ISO 604 MPa – – 85 100 140 150@ 1% deflection

Compressive Modulus ISO 604 MPa – – 10,000 14,500 21,000 21,500

Rockwell Hardness ISO 2039-2 M-Scale – – 80 85 93 –

Izod Impact: Notched ISO 180/1A KJ/m2 75 86 45 23 12 14

Izod Impact: Un-Notched ISO 180/1U KJ/m2 95 135 61 29 17 15

Charpy Impact: Notched ISO 179/1eA KJ/m2 100 59 42 26 12 12

Charpy Impact: Un-Notched ISO 179/1eU KJ/m2 125 143 48 33 16 18

Thermal

Melting Point ISO 3146 °C 212 280 280 280 280 280

Deflection Temperature ISO 75/A °C 150 168 230 235 240 23.5under Load @ 1.80 MPa

Coefficient of Thermal internal(1) cm/cm/°C – 5/75 -5/89 0/79 3/64 1/53Expansion (-50 to 200°C) x 10-6

Flow/Transverse

Electrical

Volume Resistivity IEC 93 ohm-cm – 1015 1015 1015 1015 1015

Surface Resistivity IEC 93 ohms – 1014 >1015 >1015 >1015 >1015

Dielectric Strength IEC 243-1 kV/mm – 47 34 37 3.2 381.5mm, 23°C, 50% RH

Comparative Tracking Index IEC 112 volts – 150 200 175 175 175

Arc Resistance seconds – – 135 140 180 124

Relative Permittivity: 1kHz IEC 250 – 3.3 3.3 3.7 4.5 3.7

Relative Permittivity: 1MHz – 3.0 3.0 3.7 4.1 3.55

Relative Permittivity: 1GHz – – 2.8 3.2 3.9 3.4

Dissipation Factor: 1kHz IEC 250 – – 0.030 0.019 0.006 0.005

Dissipation Factor: 1MHz – 0.020 0.018 0.018 0.018 0.008

Dissipation Factor: 1GHz – 0.040 0.006 0.006 0.006 0.002

Limiting Oxygen Index, (LOI) ISO 4589 % – – – 45 – 50

Table 3.0 · Short-term Properties of Vectra® LCP

(1) measured on 3mm cube cut from center of t-bar

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3

Table 3.0 · Short-term Properties of Vectra® LCP (continued)

Property Method Units B150 C115 C130 C150 D130M E130i

Physical ISO 1183 kg/m3 1,800 1,500 1,620 1,810 1,630 1,610

Water Absorption ISO 62 % 0.005 0.005

Mechanical @ 23°C






Compressive Strength ISO 604 MPa – 82 139 152 – 93@ 1% deflection

Compressive Modulus ISO 604 MPa – 11,000 22,000 20,500 – 14,000

Rockwell Hardness ISO 2039-2 M-Scale – – – – 65 71





Thermal


Deflection Temperature ISO 75/A °C – 250 255 255 220 276Under Load @ 1.80 MPa

Coefficient of Thermal internal(1) cm/cm/°C - 3/66 3/58 2/64 – 1/73Expansion (-50 to 200°C) x 10-6

Flow/Transverse

Electrical

Volume Resistivity IEC 93 ohm-cm 1015 1014 1015 1015 1015 1015

Surface Resistivity IEC 93 ohms 1013 >1015 >1015 >1015 >1015 1014

Dielectric Strength IEC 243-1 kV/mm – 35 35 28 – 321.5mm, 23°C, 50% RH

Comparative Tracking Index IEC 112 volts – 150 200 225 – 200

Arc Resistance seconds – 135 182 182 – 140

Relative Permittivity: 1kHz IEC 250 – 3.4 3.8 4.5 – 3.5

Relative Permittivity: 1MHz 4.0 3.1 3.7 4.1 3.9 3.3

Relative Permittivity: 1GHz 3.7 3.0 3.4 3.9 – 3.1

Dissipation Factor: 1kHz IEC 250 – 0.040 0.018 0.006 – 0.019

Dissipation Factor: 1MHz 0.020 0.020 0.018 0.018 0.033 0.025

Dissipation Factor: 1GHz – 0.007 0.004 0.006 – 0.008

Limiting Oxygen Index, (LOI) ISO 4589 % – – 45 – – 45


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Property Method Units H130 H140 H145 L115 L130 L140

Physical

Density ISO 1183 kg/m3 1,600 1,700 1,750 1,500 1,610 1,710

Water Absorption ISO 62 % 0.017 0.012 – – 0.006 —

Mechanical @ 23°C






Compressive Strength ISO 604 MPa – – – – 100 –@ 1% deflection

Compressive Modulus ISO 604 MPa – – – – 14,000 –

Rockwell Hardness ISO 2039-2 M-Scale 74 77 – – 72 69


Izod Impact: Un-Notched ISO 180/1U KJ/m2 27 27 – – 38 26

Charpy Impact: Notched ISO 179/1eA KJ/m2 24 14 10 – 23 14

Charpy Impact: Un-Notched ISO 179/1eU KJ/m2 29 24 23 – 45 32

Thermal


Deflection Temperature under Load @ 1.80 MPa ISO 75/A °C 298 306 320 – 235 240

Coefficient of Thermal internal(1) cm/cm/°C – 1/65 – – 5/65 –Expansion (-50 to 200°C) x 10-6

Flow/Transverse

Electrical

Volume Resistivity IEC 93 ohm-cm – – – – 1014 1014

Surface Resistivity IEC 93 ohms 1015 1015 1015 – 1015 1014

Dielectric Strength IEC 243-1 kV/mm 37 – – – 29 –1.5mm, 23°C, 50% RH

Comparative Tracking Index IEC 112 volts 175 200 200 – 175 175

Arc Resistance seconds – – – – 130 –

Relative Permittivity: 1kHz IEC 250 – – – – 3.8 –

Relative Permittivity: 1MHz 3.5 3.6 – 3.0 3.5 3.6

Relative Permittivity: 1GHz 3.2 3.4 – 3.0 3.3 3.3

Dissipation Factor: 1kHz IEC 250 – – – – 0.006 –

Dissipation Factor: 1MHz 0.020 0.020 – 0.020 0.024 0.020

Dissipation Factor: 1GHz – – – – 0.008 –

Limiting Oxygen Index, (LOI) ISO 4589 % 50 50 – – 45 –



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19

3

Property Method Units V140 A230 A410 A420 A422 A430

Physical

Density ISO 1183 kg/m3 1,670 1,490 1,840 1,890 1,680 1,500

Water Absorption ISO 62 % – – – – – –

Mechanical @ 23°C






Compressive Strength ISO 604 MPa 134 136 116 131 120 38@ 1% deflection

Compressive Modulus ISO 604 MPa 16,000 23,500 19,000 21,500 18,500 6,000

Rockwell Hardness ISO 2039-2 M-Scale 96 83 76 79 – –


Izod Impact: Un-Notched ISO 180/1U KJ/m2 – 16 23 17 23 67


Charpy Impact: Un-Notched ISO 179/1eU KJ/m2 – 20 24 18 26 86

Thermal


Deflection Temperature ISO 75/A °C 270 225 235 230 230 165under Load @ 1.80 MPa

Coefficient of Thermal internal(1) cm/cm/°C 10/67 -8/58 5/66 11/51 3/58 -10/10Expansion (-50 to 200°C) x 10-6

Flow/Transverse

Electrical


Surface Resistivity IEC 93 ohms 1015 102 >1015 >1015 1015 1015

Dielectric Strength IEC 243-1 kV/mm 25 34 8 6 361.5mm, 23°C, 50% RH

Comparative Tracking Index IEC 112 volts 175 175 250 225 225

Arc Resistance seconds 165 180 180 125 130

Relative Permittivity: 1kHz IEC 250 3.8 4.5 6.7 7.4 3.2

Relative Permittivity: 1MHz 3.7 4.2 6.1 6.4 2.7

Relative Permittivity: 1GHz 3.3 3.9 5.5 5.9 2.65

Dissipation Factor: 1kHz IEC 250 – 0.015 0.020 0.030 0.030

Dissipation Factor: 1MHz 0.005 0.014 0.020 0.022 0.016

Dissipation Factor: 1GHz – 0.005 0.010 0.010 0.006

Limiting Oxygen Index, (LOI) ISO 4589 % – – – – – –

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Property Method Units A435 A515 A530 A625 A700 A725

Physical

Density ISO 1183 kg/m3 1,620 1,520 1,650 1,540 1,630 1,560

Water Absorption ISO 62 % – – 0.005 – – –

Mechanical @ 23°C






Compressive Strength ISO 604 MPa 77 61 60 56 100 –@ 1% deflection

Compressive Modulus ISO 604 MPa 10,500 10,000 10,000 9,000 14,500 –

Rockwell Hardness ISO 2039-2 M-Scale – 63 – 62 85 44





Thermal


Deflection Temperature °C 230 185 185 185 232 160under Load @ 1.80 MPa ISO 75/A

Coefficient of Thermal internal(1) cm/cm/°C 0/85 -10/64 12/69 10/50 9/60 –Expansion(-50 to 200°C) x 10-6

Flow/Transverse

Electrical


Surface Resistivity IEC 93 ohms >1015 >1015 >1015 1015 106 106

Dielectric Strength IEC 243-1 kV/mm 32 40 36 n/a n/a n/a1.5mm, 23°C, 50% RH

Comparative Tracking Index IEC 112 volts 175 175 200 200 175 –

Arc Resistance seconds 130 145 180 n/a n/a n/a

Relative Permittivity: 1kHz IEC 250 3.4 3.8 3.7 25.0 n/a n/a

Relative Permittivity: 1MHz 3.1 3.2 3.2 13.0 n/a n/a

Relative Permittivity: 1GHz 3.0 3.2 3.2 5.0 n/a n/a

Dissipation Factor: 1kHz IEC 250 0.030 – 0.015 0.050 n/a n/a

Dissipation Factor: 1MHz 0.016 0.020 0.016 0.150 n/a n/a

Dissipation Factor: 1GHz 0.006 – 0.005 – n/a n/a

Limiting Oxygen Index, (LOI) ISO 4589 % – – – – – –



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21

3

Property Method Units B230 C400 C550 C810 C820 E530i E820i

Physical

Density ISO 1183 kg/m3 1,500 1,960 1,890 1,850 1,930 1,650 1,920

Water Absorption ISO 62 % 0.008 – – – – 0.006 –

Mechanical @ 23°C

Tensile Strength ISO 527 MPa 200 82 115 100 86 140 104

Tensile Modulus ISO 527 MPa 31,800 14,100 17,800 11,400 8,800 10,400 8,400

Elongation at Break ISO 527 % 0.7 0.7 2.3 3.4 2.5 3.5 3.5

Flexural Strength ISO 178 MPa 320 110 170 133 128 160 117

Flexural Modulus ISO 178 MPa 25,500 11,000 17,000 10,800 8,300 11,100 8,900

Compressive Strength ISO 604 MPa 204 – 95 – – – –@ 1% deflection

Compressive Modulus ISO 604 MPa 33,000 – 16,500 – – – –

Rockwell Hardness ISO 2039-2 M-Scale 99 – – – 75 43 60

Izod Impact: Notched ISO 180/1A KJ/m2 10 3 5 2 3 36 4

Izod Impact: Un-Notched ISO 180/1U KJ/m2 12 5 14 15 – 89 45

Charpy Impact: Notched ISO 179/1eA KJ/m2 6 3 4 3 – 29 7

Charpy Impact: Un-Notched ISO 179/1eU KJ/m2 15 7 17 25 – 84 54

Thermal

Melting Point ISO 3146 °C 280 325 325 325 325 335 335

Deflection Temperature ISO 75/A °C 235 – 225 197 181 227 220under Load @ 1.80 MPa

Coefficient of Thermal internal(1) cm/cm/°C 0/45 – 1/60 – – 9/91 –Expansion (-50 to 200°C) x 10-6

Flow/Transverse

Electrical

Volume Resistivity IEC 93 ohm-cm 10 – 1015 1015 1015 1012 –

Surface Resistivity IEC 93 ohms 102 – >1015 1015 1014 1017 1015

Dielectric Strength IEC 243-1 kV/mm – 33 33 – 32 291.5mm, 23°C, 50% RH

Comparative Tracking Index IEC 112 volts – 225 175 – – 200

Arc Resistance seconds – 183 – – – –

Relative Permittivity: 1kHz IEC 250 – 4.0 – – – –

Relative Permittivity: 1MHz 4.2 4.0 3.7 5.7 3.2 –

Relative Permittivity: 1GHz – 3.5 – – 3.2 –

Dissipation Factor: 1kHz IEC 250 – – – – – –

Dissipation Factor: 1MHz 0.015 0.010 0.014 0.017 0.020 0.030

Dissipation Factor: 1GHz – – – – – –

Limiting Oxygen Index, (LOI) ISO 4589 % – – – – – 40 –

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3.1 Mechanical properties

3.1.1 Effect of anisotropy and wall thickness

LCPs are well known to have anisotropic propertieswhen molded into parts. A result of this is a tendencyto fibrillate when abraded. Unlike other engineeringor technical polymers, LCPs become much lessanisotropic as they are formulated with glass fiberreinforcement, and to a lesser degree with mineral. An example comparing Vectra LCP with a conventional engineering resin, PBT, both with andwithout glass reinforcement is shown in Figure 3.1.1.The anisotropy of 30% glass reinforced Vectra LCPand 30% glass reinforced PBT is nearly the same indi-cating that designing for glass reinforced Vectra andother engineering resins need not be impacted byanisotropy. Management of anisotropy can be affectedby gate location and wall thickness adjustments.

Table 3.1.1 compares the anisotropy of flexural andtensile properties of various Vectra LCP grades molded in a 80 mm x 80 mm x 2 mm flat plate mold.Table 3.1.2 shows the effect of molding in a thinnerpart (80 mm x 80 mm x 1 mm) on the anisotropy ratio.

As the wall thickness or film or sheet thicknessdecreases then the highly oriented outer layer be-comes a higher percentage of the total (Figure 3.1.2).This higher percentage of highly oriented surfacelayer, in general, results in greater strength andmodulus in thinner sections (Figures 3.1.3, 3.1.4, 3.1.5,3.1.6). The excellent flow characteristics of VectraLCP enable the filling of extremely thin walls to takeadvantage of this stiffness and strength.

PBT

Ani

sotro

py R

atio

(MD

/TD

*)

* Tensile strength in machine (flow) direction/tensile strength in transverse (cross flow) direction

3.0

2.5

2.0

1.5

1.0

0.5

030%GF PBT LCP 30%GF LCP

Fig. 3.1.1 · Comparison of anisotropy* of Vectra LCP versus Celanex PBT

(ISO universal test specimen)

Fig. 3.1.2 · Micrograph of fiber structure showing orientation of outer layers.

Strand LCP extrudate shows the higher orientation in the outer “skin” layer but not in the core;

Extruded LCP fiber is highly oriented with all “skin” observed.

Table 3.1.1 · Anisotropy of properties – 2 mm thick

Unfilled 30% glass 30% mineral

filled filled

Flex strength Ratio FD/TD* 2.7 2.1 2.4

Flex modulus Ratio FD/TD* 3.6 2.9 3.9

Tensile strength Ratio FD/TD* 2.3 1.9 2.5

Tensile modulus Ratio FD/TD* 3.3 2.2 2.7

*FD/TD = anisotropy ratio – flow direction/transverse direction

Table 3.1.2 · Anisotropy of properties – 1 mm thick

Unfilled 30% glass 30% mineral

filled filled

Flex strength Ratio FD/TD* 3.9 3.1 2.9

Flex modulus Ratio FD/TD* 6.7 4.4 4.8

Tensile strength Ratio FD/TD* 3.6 2.6 3.1

Tensile modulus Ratio FD/TD* 3.0 2.5 2.8

*FD/TD = anisotropy ratio – flow direction/transverse direction

Vectra®


23

3

50,000

40,000

30,000

20,000

10,000

MPa 0.8 mm

1.6 mm

3.2 mm

4.0 mm

A530E130i L130A130H140B130 B2300

350

MPa

250

200

150

0.8 mm

1.6 mm

3.2 mm

4.0 mm

A530E130i L130A130H140B130 B230

100

50

0

40,000

30,000

20,000

10,000

MPa 0.8 mm

1.6 mm

3.2 mm

4.0 mm

A530E130i L130A130H140B130 B2300

400

MPa

300

250

0.8 mm

1.6 mm

3.2 mm

4.0 mm

A530E130i L130A130H140B130 B230

200

150

100

50

0

Fig. 3.1.3 · Tensile modulus versus wall thickness Vectra LCP

Fig. 3.1.4 · Tensile strength versus wall thickness Vectra LCP

Fig. 3.1.5 · Flexural modulus versus wall thickness Vectra LCP

Fig. 3.1.6 · Flexural strength versus wall thickness Vectra LCP

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24

3.1.2 Short term stress

The stress strain curves shown in Figure 3.1.7 arerepresentative of the Vectra LCP product line. Vectra A130 is a 30% glass filled resin, Vectra B230 is a 30% carbon fiber reinforced resin, Vectra A430 isa 25% PTFE filled resin, Vectra L130 is a 30% glass filled resin, Vectra H145 is a 45% glass filled resin.These five products essentially cover the range ofelongation (strain) for filled or reinforced Vectra LCPgrades. Like most other filled or reinforced semi-crystalline plastics, Vectra LCP has no yield point.Even unfilled LCP has no yield point.

As with any thermoplastic resin, stiffness and strengthof the materials decrease with increasing temperature.Figures 3.1.8a and b show the influence oftemperature on the stress strain curves of Vectra B230(carbon fiber filled, high strength and stiffness), andVectra E130i (glass fiber filled, high temperature).

Stre

ss (M

Pa)

250

200

150

100

50

0

Strain (%)0 1.0 3.0 4.0 5.0 6.0 7.02.0

B230

H145

L130

A130

A430

Fig. 3.1.7 · Stress strain curves at 23°C

The influence of temperature on tensile properties fora number of Vectra LCP grades is given in Figures3.1.9 and 3.1.10.

Stre

ss (M

Pa)

250

200

150

100

50

0

Strain (%)0 0.2 0.6 0.8 1.0 1.4 1.60.4 1.2

-40°C 23°C

80°C

120°C

200°C

Fig. 3.1.8a · Influence of temperature on stress strain behavior, Vectra B230

Stre

ss (M

Pa)

250

200

150

100

50

0

Strain (%)0 0.2 0.6 0.8 1.0 1.4 1.60.4 1.2

-40°C

23°C

120°C

200°C

1.6

80°C

Fig. 3.1.8b · Influence of temperature on stress strain behavior, Vectra E130i

-40°C

23°C

80°C

120°C

200°C

A5300

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

B130 B230 E130i E530i L130 H140

Tens

ile M

odul

us (M

Pa)

Fig. 3.1.9 · Tensile modulus versus temperature, Vectra LCP

Vectra®


3

-40°C

23°C

80°C

120°C

200°C

A530

Tens

ile S

treng

th (M

Pa)

0

50

100

150

200

250

B130 B230 E130i E530i L130 H140

Fig. 3.1.10 · Tensile strength versus temperature, Vectra LCP

3.1.3 Behavior under long term stress

Vectra LCP has good resistance to creep. Figures3.1.11 and 3.1.12 show the tensile creep modulus oftwo high temperature resins, Vectra E130i and VectraH140, for exposure at 23°C and 120°C at variousstress levels. The maximum exposure time was 1,000hours for E130i and 1,500 hours for H140. The stresslevels were chosen to be 30% of the short-term failurestress and none of the samples failed in testing. Nosign of creep rupture – a common form of failure –was observed at stress levels below 30%.

Figures 3.1.13, 3.1.14 and 3.1.15 show flexural creepmodulus for Vectra A130, Vectra B130, and VectraC130 – all 30% fiberglass reinforced resins.

Tens

ile C

reep

Mod

ulus

(MPa

)

16,000

14,000

12,000

10,000

8,000

6,000

Time (hours)1 10 103102

4,000

2,000

0

23°C/40 MPa

23°C/30 MPa

120°C/30 MPa

120°C/20 MPa

120°C/40 MPa

Fig. 3.1.11 · Tensile creep modulus , Vectra E130i

Flex

ural

Cre

ep M

odul

us (M

Pa)

20,000

15,000

10,000

8,000

6,000

Time (hours)10-2 1 103102

4,000

2,000

1,00010-1 10

23°C

120°C

80°C

Maximum Stress = 50 MPa

Fig. 3.1.13 · Flexural creep modulus, Vectra A130

Tens

ile C

reep

Mod

ulus

(MPa

)

26,000

14,000

12,000

10,000

8,000

6,000

Time (hours)1 10 104103

4,000

2,000

0

23°C/30 MPa

120°C/20 MPa

16,000

18,000

20,000

22,000

24,000

102

120°C/30 MPa

23°C/40 MPa

120°C/40 MPa

Fig. 3.1.12 · Tensile creep modulus, Vectra H140

25

Vectra®


26

Flex

ural

Cre

ep M

odul

us (M

Pa)

30,000

8,000

6,000

4,000

3,000

Time (hours)10-2 10 103102

2,000

1,000

10,000

20,000

10-1 1

23°C

80°C


Fig. 3.1.14 · Flexural creep modulus, Vectra B130

Flex

ural

Cre

ep M

odul

us (M

Pa)

Time (hours)10-2 10 10310210-1 1

30,000

8,000

6,000

4,000

3,000

2,000

1,000

10,000

20,000

23°C


80°C

120°C

Fig. 3.1.15 · Flexural creep modulus, Vectra C130

3.1.4 Notch sensitivity (Impact testing)

Vectra LCP has very high notched and unnotchedCharpy and Izod impact strength. The toughnessdevelops as the melt flows into a mold cavity. Themolecules are oriented by the “fountain flow” effectgenerating a highly oriented skin and a moderatelyoriented core. When a “notch” is in a molded part, i.e. asharp inside corner, the “notch” is quite resistant tofailure because of the wood-like fibrous structure. Ifthis fibrous structure is cut by notching, as in a notchedIzod or Charpy specimen, the energy to break is stillhigh compared with other glass reinforced resins.

The values for notched and unnotched impact are included in Table 3.0 with other short termproperty data.

3.1.5 Fatigue

Components subject to periodic stress must bedesigned on the basis of fatigue strength, i.e. the cyclicstress amplitude sa determined in the fatigue test – at a given mean stress sm – which a test specimenwithstands without failure over a given number ofstress cycles, e.g. 107 (Wöhler curve). The variousstress ranges in which tests of this nature areconducted are shown in Figure 3.1.16

For most plastics, the fatigue strength after 107 stresscycles is about 20 to 30% of the ultimate tensilestrength determined in the tensile test. It decreaseswith increasing temperature, stress cycle frequencyand the presence of stress concentration peaks innotched components.

The Wöhler flexural fatigue stress curves for threeVectra LCP grades are shown in Figure 3.1.17. Theflexural fatigue strength of Vectra A130 after 107 stresscycles is sbw = 50 N/mm2.

+ s

range forfluctuating stresses

(under compression)

– s



(under tension)

sm ≥ sa sm ≥ sa sm ≥ sa

sm

> s

a

sm

= 0

sm

< s

a

su =

0s

m =

sa

sm

> s

a

sm

= s

as

u = 0

sm

> s

a time

com

-pr

essi

on–

+ te

nsio

n

Fig. 3.1.16 · Stress Ranges in Fatigue Tests

Stre

ss a

mpl

itude

± s

a (M

Pa)

120

100

80

60

Number of stress cycles N103 105 107106

40

20

0104

a

bc

test temperature 23°Cstress cycle frequency 10 Hzmean stress sm = 0

Fig. 3.1.17 · Wöhler curves for Vectra A130 (a),Vectra B230 (b) and Vectra A530 (c), longitudinal

direction determined in the alternating flexural stress range

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3.1.6 Tribological properties

The friction and wear characteristics of Vectra LCPare very specific to the application. In general, Vectraresins have performed satisfactorily in low loadfriction and wear applications. Typical wear grades ofVectra LCP contain PTFE, carbon fibers, graphiteflake, or a combination of these and other fillers andreinforcements. Coefficients of friction typically rangefrom 0.1 to 0.2. More specific data are available withstandardized tests (Table 3.1.3). However werecommend that your specific bearing, friction andwear applications be reviewed with Vectra LCPtechnical service engineers.

Figure 3.1.18 compares the dynamic coefficient offriction, µ, of a number of Vectra LCP grades slidingagainst steel to that of acetal or POM, plus wear whiledry sliding on a rotating steel shaft.

Dynamic coefficient of friction, µ, of Vectra LCP sliding against steel compared to Celcon/HostaformAcetal Copolymer (POM); (steel ball diameter 13 mm, load FN = 6 N, sliding speed v = 60 cm/min).

Wear of Vectra compared to Celcon/HostaformAcetal Copolymer (POM) in dry sliding on a rotatingground steel shaft (roughness height = 0.1 µm, peripheral speed of the shaft v = 136 m/min, load FN = 3 N, duration of test 60 hr)

Vectra LCP has moderate surface hardness. Rockwellhardness (M scale) of up to 100 have been achieved(See Table 3.0, short term properties)

3.1.7 Damping

The unique structural characteristics of Vectra LCPgreatly affect the damping characteristics. Generallyspeaking, materials with high modulus such as metalshave low damping (internal loss) characteristics andlow modulus materials such as rubbers have highdamping characteristics. Vectra LCP, however,exhibits high damping characteristics despite theirhigh modulus. This is due to the rigid rod likecrystalline structure of the LCP.

The relationship between internal loss, h, and damping factor, l, is as follows:

lT/p = h

where T = cycle and p = 3.14…….

Table 3.1.3 · Coefficient of Friction, µ, of Vectra LCP (ASTM D1894)

Description Vectra LCP Coefficient of Friction – Grade Flow Direction

Static Kinetic

A115 0.11 0.11

Glass Fiber Reinforced A130 0.14 0.14

A150 0.16 0.19

Carbon Fiber Reinforced A230 0.19 0.12

A410 0.21 0.21

Mixed Filler/Fiber A420 0.20 0.17

A422 0.16 0.18

PTFE ModifiedA430 0.16 0.18

A435 0.11 0.11

Mineral ModifiedA515 0.20 0.19

A540 0.12 0.12

Graphite Flake A625 0.21 0.15

Carbon Fiber Reinforced B230 0.14 0.14

Glass Fiber Reinforced L130 0.15 0.16

A430

POM

A435

A625

Dynamic coefficientof friction µ*

B230

A530

C130

0.4

A230

B130

A422

A130

Wear* (mm3)

*average from longitudenal and transverse to flow direction

0.3 0.2 0.1 0 5 10 15

Fig. 3.1.18 · Friction and Wear

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28

100

Internal loss

0 0.02 0.04 0.06 0.08 0.10 0.20

8060

40

20

1086

4

2

1

Tens

ile M

odul

us (M

Pa)

Tens

ile M

odul

us (k

gf/c

m2 )

x 104

1008060

40

20

1086

4

2

1

x 103

POM

PE

PBT

Aluminium

Vectra A230

Vectra A950

Rubber

Fig. 3.1.19 · Damping Properties

Flex Modulus (MPa)0 10,000 20,000

14

Dam

ping

Fac

tor

(1/s

ec)

6

12

10

8

30,000

A950

A230A130

A410B230

C130

C810

A430

Fig. 3.1.20 · Vibration Characteristics

3.2 Thermal properties

3.2.1 Dynamic mechanical spectra

A snapshot view of the thermomechanical behavior ofplastic materials is provided by Dynamic MechanicalAnalysis (DMA). This technique is used to scan themodulus or stiffness ( E’) and damping or energydissipation (tan d) behavior of a material over a widetemperature range. The stiffness or modulus (E’)corresponds to and has nearly the exact value as theconventional tensile modulus (E) in temperatureregions of low loss or damping factor. This modulusrepresents the recoverable elastic energy stored in aviscoelastic material during deformation. The damping factor (tan d) represents the energy losses occurringduring deformation due to internal molecular frictionthat occurs in a viscoelastic material.

By comparing DMA curves of two or more VectraLCPs (Figures 3.2.1-3.2.8), retention of stiffness astemperatures are raised is easily compared. Generallythe higher the stiffness at any temperature, the morecreep resistant the variants will be at that temperature.In Table 3.2.1 the temperature where the modulus hasfallen to 50% of the ambient temperature modulusvalue is tabulated for a series of Vectra LCPs.Generally, the higher this temperature, the more creepresistant the variant will be at elevated temperatures.For example, Vectra A130 (T1/2E = 208ºC) will bemore creep resistant than Vectra A530 (T1/2E = 126ºC) in the temperature range of about 120to 210ºC. Likewise, Vectra E130i (T1/2E = 282ºC) willbe more creep resistant than Vectra A130 (T1/2E =208ºC) in the 210 to 280ºC temperature range.

Similarly, peaks in the tan d indicate transitions andtemperature ranges where the polymer will be moreenergy-dissipating (note that the frequency of themeasurements is very, very low, on the order of oneHertz [cycle/second]. This frequency is well belowthe audible sound range of 20-20,000 Hertz. Typically,Vectra LCP polymers have two strong damping peaksat the glass transition, a, and at a lower temperaturetransition, b. These are tabulated in Table 3.2.1.Typically, the damping peaks for all Vectra LCPs fallover a wide range of temperature. Glassy transitionsare usually in the 120 to 155ºC range with the lowertemperature secondary loss peak at 10 to 80ºC. Ingeneral, the temperatures of the damping peaks at justabove ambient make Vectra LCP a good soundabsorber. When struck, they do not “ring”, they“clunk” or sound “dead”.

Figure 3.1.19 shows the damping properties of variousmaterials. Figure 3.1.20 compares the vibrationcharacteristics of Vectra LCP grades.

Vectra®


3

Tens

ile M

odul

i (M

Pa)

104

103

102

101

100

tan

d

Temperature (°C)-50-50 0 50 100 200 250 300150 350

10-2

10-1

E’

E’’

tan d

Fig. 3.2.1 · Dynamic Mechanical AnalysisVectra A130

Tens

ile M

odul

i (M

Pa)

104

103

102

101

100

tan

d

Temperature (°C)-50-50 0 50 100 200 250 300150 350

10-2

10-1

E’

E’’

tan d

Fig. 3.2.2 · Dynamic Mechanical AnalysisVectra A530

Tens

ile M

odul

i (M

Pa)

104

103

102

101

100

tan

d

Temperature (°C)-50-50 0 50 100 200 250 300150 350

10-2

10-1

E’

E’’

tan d

Fig. 3.2.4 · Dynamic Mechanical AnalysisVectra B230

Tens

ile M

odul

i (M

Pa)

104

103

102

101

100

tan

d

Temperature (°C)-50-50 0 50 100 200 250 300150 350

10-2

10-1

E’

E’’

tan d

Fig. 3.2.3 · Dynamic Mechanical AnalysisVectra B130

Tens

ile M

odul

i (M

Pa)

104

103

102

101

100

tan

d

Temperature (°C)-50-50 0 50 100 200 250 300150 350

10-2

10-1

E’

E’’

tan d

Fig. 3.2.5 · Dynamic Mechanical AnalysisVectra E130i

Table 3.2.1 · Dynamic mechanical analysis

Sample ID a transition b transition Modulus E Half Modulus(Tg) (°C) (°C) at 23°C Temperature

(MPa) T1/2E (°C)

Vectra A130 119 54 5,140 208

Vectra A530 119 50 5,005 126

Vectra B130 157 72 5,680 189

Vectra B230 159 79 5,870 216

Vectra E130i 135 23 4,310 282

Vectra E530i 130 22 4,075 204

Vectra H140 130 16 5,220 290

Vectra L130 130 11 5,210 238

29

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30

3.2.2 Deflection temperature under load

The Deflection Temperature under Load (DTUL)measured at 1.8 MPa for Vectra LCP ranges from alow of 120°C for an unreinforced, low temperatureproduct to as high as 320°C for the glass fiberreinforced high heat products. Although values forDTUL can be measured at loads of 8 MPa, 1.8 MPaand 0.45 MPa, values are most frequently reported forcrystalline materials at 1.8 MPa. This value is providedfor all Vectra LCP grades in Table 3.0 with the short-term property data.

3.2.3 Coefficient of linear thermal expansion

One of the advantages of Vectra LCP is its very lowcoefficient of linear thermal expansion (CLTE) incomparison with other thermoplastics (Table 3.2.2).The expansion coefficient displays marked anisotropy.It is much lower in the orientation direction than thecross flow direction. With very high orientation in theflow direction, the expansion coefficient may even benegative, especially for carbon fiber reinforced grades.

The expansion coefficient of Vectra LCP can be variedwithin certain limits and matched to the expansioncoefficient of glass, steel, ceramic, or glass fiber/epoxysubstrates. Figure 3.2.9 compares the expansioncoefficients of various engineering materials. Whencomposite structures of Vectra LCP and othermaterials are heated, no thermally induced stressesoccur because the thermal expansion values aresimilar. Components for surface mounting shouldhave expansion coefficients closely in line with thoseof the circuit board substrate (usually FR 4 epoxy

Tens

ile M

odul

i (M

Pa)

104

103

102

101

100

t an

d

Temperature (°C)-50-50 0 50 100 200 250 300150 350

10-2

10-1

E’

E’’

tan d

Fig. 3.2.7 · Dynamic Mechanical AnalysisVectra H140

Tens

ile M

odul

i (M

Pa)

104

103

102

101

100

tan

dTemperature (°C)

-50-50 0 50 100 200 250 300150 35010-2

10-1

E’

E’’

tan d

Fig. 3.2.6 · Dynamic Mechanical AnalysisVectra E530i

Tens

ile M

odul

i (M

Pa)

104

103

102

101

100

tan

d

Temperature (°C)-50-50 0 50 100 200 250 300150 350

10-2

10-1

E’

tan d

E’’

Fig. 3.2.8 · Dynamic Mechanical AnalysisVectra L130

Table 3.2.2 · Typical CLTE values of Vectra LCP versus other engineering thermoplastics

Flow Cross Flow

Vectra LCP 30% Glass fiber 0 to 5 x 10-6/°C 40 to 80 x 10-6/°Creinforced

Vectra LCP 40% Mineral 10 to 15 x 10-6/°C 50 to 70 x 10-6/°Cfilled

Vectra LCP 30% Carbon fiber -3 to -1 x 10-6/°C 45 to 65 x 10-6/°Creinforced

Fortron PPS 40% Glass fiber 7 to 14 x 10-6/°C 40 to 90 x 10-6/°Creinforced

Celanex PBT 30% Glass fiber 45 to 50 x 10-6/°C -reinforced

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3

resin/glass fiber) to avoid mechanical stresses at thesoldering points as a result of thermal loading. VectraLCP is therefore a good material to consider forcomposite structures, particularly for surface mounttechnology (SMT) components.

Glass

CTE (x 10-6/°C)0 20 40 60 10080

Steel

Ceramic

FR4 epoxy/glass fibre

Vectra (inflow direction)

Vectra (transverse toflow direction)

Copper

Aluminium

PPS

PBT (inflow direction

PA (inflow direction

min.max.

Fig. 3.2.9 · Coefficients of Linear Thermal Expansion of Selected Engineering Materials

The expansion coefficient is dependent on the flow-induced orientation in the part. The more balanced theflow through a given section of the part, the morebalanced the expansion coefficient in the flow and thecross flow directions. Table 3.2.3 compares theexpansion coefficient of select Vectra LCP grades inthree geometries.

As shown in Figure 3.2.10 the orientation in the ISOuniversal tensile bar is higher than that in the flex barbecause of converging flow as the bar narrows in thecenter. This increase in orientation in the flowdirection in the ISO test bar is reflected in the higheranisotropy of the CLTE data. As the flow and theorientation becomes more balanced in the 100 mmdisk configuration, the CLTE values become morebalanced also.

CrossFlow

Flow directionGate

Flow direction

CrossFlow

Gate

Flow direction

CrossFlow

Gate

a) 127 x 12.7 x 3.2 mm flex bar

b) 100 mm diameter x 3.2 mm disk

c) 100 mm x 4 mm universal test specimen

Fig. 3.2.10 · Sample Geometry for CLTE measurements

Table 3.2.3 · Coefficient of Linear Thermal Expansion (-50 to 200°C)

Coefficient of Linear Thermal Expansion (x10-6/°C)

Vectra 4 mm 3.2 mm 100 x 3.2 mm ISO Bar ASTM flex bar ASTM disk

Flow Cross Flow Flow Cross Flow Flow Cross Flow

A130 0 79 3 62 11 19

A530 12 69 10 87 11 50

B130 1 53 4 34 9 16

B230 0 45 0 40 11 42

E130i 1 73 2 46 9 23

E530i 9 91 12 74 13 35

H140 1 65 4 38 8 21

L130 5 65 7 54 10 11

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32

3.2.4 Soldering compatibility

Parts molded from Vectra LCP are commerciallysuccessful in applications requiring vapor phase,infrared and wave soldering. They have excellentdimensional stability and exhibit very low andpredictable shrinkage after exposure to surface mount temperatures minimizing any tendency to bow or warp.

Table 3.2.4 shows dimensional changes on a 56 mm long connector with 40 contacts afterimmersion in Fluorinert FC70, which is used in Vapor Phase soldering.

Resistance to soldering temperatures of a number ofVectra LCP grades is given in Table 3.2.5. Experiencehas shown that Vectra A130 has acceptable resistanceto solder temperatures up to 240°C. Above thistemperature, parts can begin to soften or distort dueto the proximity to the melting point (280°C). VectraC130 can be used up to temperatures of 260°C,however, again, parts can soften or distort above thistemperature as one approaches the melting point(320°C). Vectra E130i, with its much higher meltingpoint (335°C), is able to withstand solderingtemperatures of up to 300°C for a brief period of time.

Change in Dimensions after Immersion in Fluorinert FC70 at 215°C (%)

45 sec immersion 120 sec immersion

Vectra A130 (30% GF) DL 0.05 0.05DW 0.05 0.05DD 0.05 0.05

PBT (30% GF) DL 0.2 0.22DW 0.3 0.5DD 0.2 0.32

PPS (40% GF) DL 0.15 0.16DW 0.53 0.55DD 0.55 0.57

GF = fiber glass reinforcedDL = change in length dimension (%)DW = change in width dimension (%)DD = change in depth dimension (%)

Table 3.2.4 · Vapor Phase Soldering Stability of Vectra LCP

3.2.5 Thermodynamics, phase transition

Figure 3.2.11 shows the Specific Heat, Cp, of VectraLCP as a function of temperature compared to PPSand PBT. Vectra LCP has a lower Specific Heat thanpartially crystalline thermoplastics. The curves aremore like those for amorphous thermoplastics. This is attributed to the liquid crystalline structure of LCP. With LCP, the transition from the solid tothe melt phase is associated with a relatively smallchange in the state of order since the melt is alreadyhighly oriented.

Because of the high order of the melt state and theability to solidify with minimal change in structure,the transition energy during melting or freezing ofVectra LCP is an order of magnitude less than that ofpartially crystalline thermoplastics (Figure 3.2.12)

Figure 3.2.13 shows the relative enthalpy phasetransition energies of Vectra A130, Celanex PBT andFortron PPS throughout the heating or cooling cycle.

Solder Bath Dipping Time Vectra Vectra Vectra Temperature (°C) (sec) A130 C130 E130i

240 10 O

60 O

260 15 O

20 D

45 D

60 D O

280 10 -- O

30 -- O

45 -- D

60 -- D

90 -- -- O

290 60 -- -- O

300 30 -- -- O

310 10 -- -- O

15 -- -- D

O = no change in appearance -- = not testedD = change in appearance

Table 3.2.5 · Soldering Compatibility of Vectra LCP

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3

In designing the optimum processing machinery and parts, it is essential to know how much heat mustbe supplied or removed during processing. WithVectra LCP less heat has to be removed and the meltfreezes rapidly. This means that much faster cyclesare possible than with partially crystalline materials,thus permitting lower-cost production of parts.The thermal conductivity, l, of unreinforced VectraLCP is in the same range as that for partiallycrystalline polymers. Thermal conductivity isincreased by the use of fillers and reinforcements(Figure 3.2.14).

Spec

ific

heat

cp

(

)

6

5

4

3

Temperature (°C)0 350

2

1

050 100 150 200 250 300

Celanex PBT

Fortron PPS

Vectra A130

kJkg

· K

Fig. 3.2.11 · Specific Heat

Nylon 6,6

PET

PBT

PPS

Heat of Fusion (J/g)0 50

Vectra A130

5 15 20 35 40 4510 25 30

Fig. 3.2.12 · Phase Transition energy

Enth

alpy

(

)

500

400

300


200

100

050 100 150 200 250 300

Celanex PBT

Fortron PPS

Vectra A130

kJ kg

Fig. 3.2.13 · Enthalpy

Ther

mal

Con

duct

ivity

(

)

0.55

0.4

0.35


0.3

0.25

0.250 100 150 200 250 300

A430

L130

E530i0.45

0.5

B230

W m · °

C

Fig. 3.2.14 · Thermal conductivity

Vectra®


3.3 Flammability and combustion

Vectra LCP is inherently flame retardant (i.e. requiresno additive package) and self-extinguishing. Onexposure to very high flame temperatures, the fullyaromatic polymers form a carbon char layer, whichretards the development of flammable gases.

Vectra LCP has a self-ignition temperature of over 540°C. The onset of thermal degradation in air is not significant until temperatures over 350°C arereached (as much as 400°C for the higher melt point polymers).

The Limiting Oxygen Index (LOI) represents theminimum amount of oxygen as a percentage in air atwhich the combustion of the polymer will continueafter ignition without an additional source of energy.The LOI of Vectra LCP ranges from 40% to 50%depending on the base polymer (Table 3.0, short-term properties).

Smoke density measurements and products ofcombustion for a typical Vectra LCP, Vectra A950, are given in Table 3.3.1 and Table 3.3.2. Combustionproducts are primarily carbon dioxide, carbonmonoxide and water. In the Ohio State University(OSU) heat release test, results are also very good(Table 3.3.3).

Vectra LCP conforms to Underwriters LaboratoryUL 94 V-0 at thickness’ as low as 0.4 mm with manygrades. The UL listings for many of the commercialVectra LCP grades are given in Table 3.3.4. Thelistings can be found at UL under file number E83005.

Please note that Ticona is continuously developingnew grades of Vectra LCP, or adding to the dataalready available for current grades. Please call yourVectra LCP Technical representative for the most upto date information from UL.

Table 3.3.2 · Products of Combustion of Vectra A950, ppm (National Bureau of Standards

Smoke Density Chamber, ASTM E-662)(Generated on 3.2 x 76.2 x 76.2 mm plaques )

Thickness1.6 mm 3.2 mm

Flaming Smoldering Flaming Smoldering

Chlorine 0 0 0 0

Phosgene 0 0 0 0

Hydrogen chloride 0 0 0 0

Hydrogen fluoride 0 0 0 0

Formaldehyde <2 0 <2 0

Ammonia 0 0 0 0

Carbon monoxide 320 <10 300 <10

Carbon dioxide 8000 600 7000 600

Nitrogen oxides 5 <2 12 <2

Hydrogen cyanide <2 0 <2 0

Sulfur dioxide 0 0 0 0

Hydrocarbons as n-octane 250 0 300 0

Table 3.3.1 · Smoke Density of Vectra A950(National Bureau of Standards Smoke Density

Chamber, ASTM E-662)

Thickness1.6 mm 3.2 mm

Flaming Smoldering Flaming Smoldering

Specific smoke density 0 0 0 0after 1.5 minutes

Specific smoke density 7 0 3 0after 4.0 minutes

Maximum value for 95 2 94 1specific smoke density

Time to smoke density of 17 20 17 1990% of maximum value (minutes)

Thickness of Accumulative heat release Maximum rate of test plaque after 2 minutes (kW/cm2) heat release (kW/cm2)

1.6 mm 16.8 57.8 (after 177 seconds)

3.2 mm 2.4 59.2 (after 293 seconds)

Specification (FAR) <65 <65

Meets U.S. Federal Air Regulation, FAR25.853 (A-1), part IV, appendix Fgoverning materials used in aircraft

Table 3.3.3 · Heat Release of Vectra A950(Ohio State University)

34

Vectra®


35

3

Table 3.3.4 · Underwriters Laboratories listings for Vectra LCP

Material Color Minimum UL 94 Temperature Index Hot Wire High High D 495 IECDesignation Thickness Flam. Ignition Amp Volt Arc 112

mm Class Arc Track Resistance TrackIgnition Rate (CTI)

Elec. MechanicalWith WithoutImpact Impact

A950 NC, BK 0.42 94V-0 240 220 220 2 4 4 - -1.5 94V-0 240 220 220 2 4 4 - -3.0 94V-0 240 220 220 1 4 2 5 4

A115 NC, BK 0.44 94V-0 130 130 130 - - - - -0.85 94V-0 240 220 220 - - - - -1.5 94V-0 240 220 220 2 4 4 - -3.0 94V-0 240 220 220 1 4 2 5 4

A130+) NC, BK 0.45 94V-0 130 130 130 - - - - -ALL 0.85 94V-0 240 220 220 - - - - -

1.5 94V-0 240 220 220 2 4 0 - -3.0 94V-0 240 220 220 1 4 0 5 4

NC 1.6 94-5VA 240 220 220 2 4 0 - -

A150 NC, BK 0.45 94V-0 130 130 130 - - - - -0.79 94V-0 220 220 220 - - - - -1.57 94V-0 220 220 220 1 4 - - -3.18 94V-0 220 220 220 1 4 0 4 36.35 94V-0 220 220 220 0 4 - - -

NC 1.57 94-5VA 220 220 220 1 4 - - -3.18 94-5VA 220 220 220 1 4 0 4 3

B130 NC, BK 0.43 94V-0 130 130 130 - - - - -

C115 NC 0.44 94V-0 130 130 130 - - - - -0.81 94V-0 240 200 220 3 4 - - -1.5 94V-0 240 200 220 2 4 - - -3.0 94V-0 240 200 220 1 4 0 6 4

C130+) ALL 0.38 94V-0 130 130 130 4 4 - - -0.75 94V-0 240 220 220 1 4 - - -1.5 94V-0 240 220 240 1 4 - - -3.0 94V-0 240 220 240 0 4 0 5 4

NC 1.5 94-5VA 240 220 240 1 4 - - -3.0 94-5VA 240 220 240 0 4 0 5 4

C150 NC, BK 0.45 94V-0 130 130 130 - - - - -0.84 94V-0 220 200 220 - - - - -1.57 94V-0 220 200 220 2 4 - - -3.18 94V-0 220 200 220 1 4 0 5 3

E130i+1) BK 0.43 94V-0 130 130 130 - - - - -NC 0.75 94V-0 240 220 220 2 4 - - -ALL 1.5 94V-0 240 220 240 1 4 - - -

3.0 94V-0 240 220 240 0 4 0 5 4

H130+4) NC, BK 1.5 94V-0 130 130 130 0 4 - - -3.0 94V-0 130 130 130 0 4 0 4 4

H140+) NC, BK 1.5 94V-0 130 130 130 0 4 - - -3.0 94V-0 130 130 130 0 4 0 4 4

L115 BK 0.86 94V-0 130 130 130 - - - - -NC 1.5 94V-0 130 130 130 - - - - -

L130+) NC, BK, GY 0.84 94V-0 240 200 220 1 2 - - -

L130XL+) ALL 1.5 94V-0 240 200 220 1 2 - - -3.0 94V-0 240 200 220 0 2 3 6 4

L140 NC, BK 0.84 94V-0 130 130 130 1 2 - - -1.5 94V-0 130 130 130 1 1 - - -3.0 94V-0 130 130 130 0 0 0 5 4

V140 NC, BK 0.38 94V-0 130 130 130 - - - - -

Vectra®


36

Table 3.3.4 · Underwriters Laboratories listings for Vectra LCP (continued)

Material Color Minimum UL 94 Temperature Index Hot Wire High High D 495 IECDesignation Thickness Flam. Ignition Amp Volt Arc 112

mm Class Arc Track Resistance TrackIgnition Rate (CTI)

Elec. MechanicalWith WithoutImpact Impact

A230 NC (BK) 0.43 94V-0 130 130 130 - - - - -

A410 NC, BK 0.45 94V-0 130 130 130 - - - - -1.57 94V-0 130 130 130 1 4 - - -3.18 94V-0 130 130 130 1 4 0 5 36.35 94V-0 130 130 130 0 4 - - -

A420 NC (BK) 0.91 94V-0 130 130 130 - - - - -1.5 94V-0 130 130 130 - - - - -3.0 94V-0 130 130 130 - - - - -

A422 NC (BK) 0.45 94V-0 130 130 130 - - - - -0.81 94V-0 130 130 130 - - - - -

A430 NC, BK 0.43 94V-0 130 130 130 - - - - -

A435 NC 0.44 94V-0 130 130 130 - - - - -0.9 94V-0 130 130 130 2 1 - - -1.7 94V-0 130 130 130 1 2 - - -3.0 94V-0 130 130 130 0 2 0 5 3

A515 NC 0.38 94V-0 130 130 130 - - - - -1.5 94V-0 130 130 130 2 4 - - -3.0 94V-0 130 130 130 1 4 0 5 4

A530 NC, BK 0.46 94V-0 130 130 130 - - - - -NC 3.3 94-5VA 130 130 130 - - - - -

A625+2) NC (BK) 0.45 94V-0 130 130 130 - - - - -

A700 NC (BK) 0.42 94V-0 130 130 130 - - - - -

A725 NC (BK) 0.83 94V-0 130 130 130 0 - - - -1.5 94V-0 130 130 130 - - - - -3.0 94V-0 130 130 130 - - - - -

B230 NC (BK) 0.46 94V-0 130 130 130 - - - - -

* C400 NC 1.5 94V-0 - - - - - - - -

C550 NC 1.5 94V-0 130 130 130 - - - - -

C810 NC 0.33 94V-0 130 130 130 - - - - -0.80 94V-0 130 130 130 - - - - -

* C820 NC 0.39 94V-0 130 130 130 - - - - -

E820i NC 1.5 94V-0 130 130 130 0 4 - - -3.0 94V-0 130 130 130 0 4 0 4 4

NC = natural color, BK = black, GY = grey

* Polyplastics Co. LTD Vectra Div. UL-file number E106764+) Virgin and Regrind from 1 to 50% by weight inclusive have the same basic material characteristics.+1) Virgin and Regrind from 1 to 25% by weight inclusive have the same basic material characteristics.

In addition 26 to 50% regrind by weight inclusive have the same characteristics at a minimum thickness of 1.5 mm except the RTI for the mechanical with impact property is 180°C.

+4) Virgin and regrind from 1 to 25% by weight inclusive have the same basic material characteristics. In addition 26 to 50% regrind by weight inclusive have the same flammability and electrical properties.

+2) Virgin and regrind from 1 to 25% by weight inclusive have the same basic material characteristics. In addition 26 to 50% regrind by weight inclusive have the impact property.

+3) Virgin and regrind from 1 to 25% by weight inclusive have the same basic material characteristics in the minimum thickness of 1.5 mm except impact property.

Material designation may be followed by suffixes D-1, -2 or -3 to indicate specific colors.

Vectra®


37

3

3.4 Electrical properties

Vectra LCP resins exhibit good electrical properties(Table 3.0, short term properties). The electrical characteristics combined with easy processing, dimensional stability, heat resistance and mechanicalintegrity make Vectra LCP a good choice for electronic components, especially for applicationsinvolving surface mount technology. Vectra LCP isalso available with low to moderate conductivity(Table 3.4.1). These products are suitable for staticdissipating (ESD) applications and limitedelectromagnetic interference (EMI) applications.

Table 3.4.2 and Table 3.4.3 give the Relative Permittivity, «r, (Dielectric Constant) and DielectricLoss Tangent, d, (Dissipation Factor) for differentfrequencies for a select number of Vectra LCP products.

The Relative Permittivity, «r, (Dielectric Constant)and Dielectric Loss Tangent, d, (Dissipation Factor) asa function of temperature and frequency for VectraC130 are shown in Figures 3.4.1 and 3.4.2 respectively.The shape and magnitude of the curves are typical forglass filled Vectra LCP.

Underwriters Laboratories (UL) has evaluated themajority of Vectra LCP grades. They report measure-ments of flammability, arc resistance, hot wireignition, high current arc ignition, high voltage arcingrates, and comparative tracking index. The data isreported on the standard UL “Yellow Card”. ManyVectra LCP products allow the use of 50% regrindwhile continuing to maintain the UL rating.

In addition, UL also establishes a Relative ThermalIndex (RTI). Based on thermal aging measurements,the RTI for a given formulation gives a guideline

Vectra Vectra Vectra VectraA230 A700 A725 B230

Carbon fiber Carbon black Graphite/ Carbon fibercarbon black

Volume Resistivity* 10 to 102 104 to 106 104 to 106 10 to 102

(ohm-cm)

Surface Resistivity 102 to 103 105 to 107 105 to 107 102 to 103

(ohms)

* Measured on molded bars, silver painted ends

Table 3.4.1 · Vectra LCP Conductive Grades

A130 B130 E130i H140 L130 E820i LKX1113

100 Hz 4.2 4.0 4.0 4.1 4.1

1kHz 3.7 3.7 3.5 3.8 2.7

10 kHz 4.0 3.6 3.5 3.7

100 kHz 3.5 3.6 3.4 3.6

1 MHz 3.7 3.6 3.3 3.6 3.5 3.6 2.7

10 MHz 3.2 3.5 3.2 3.3

100 MHz 3.5 3.5 3.2 3.3

1 GHz 3.2 3.4 3.1 3.4 3.3 2.7

2 GHz 3.9

Table 3.4.2 · Relative Permittivity, «r, (Dielectric Constant)

temperature for long term retention of propertiessuch as dielectric strength, tensile strength(mechanical strength without impact) and tensileimpact strength. Vectra LCP have been assigned ageneric rating of 130°C based on their chemistry andhistoric performance, before testing is complete.

The UL listings, including RTI, for many of thecommercial Vectra LCP grades are given in Table3.3.4. Please note that Ticona is continuouslydeveloping new grades of Vectra LCP, or adding tothe data already available for current grades. Pleasecall your Vectra LCP Technical representative for themost up to date information from UL.

A130 B130 E130i H140 L130 E820i LKX1113

100 Hz 0.016 0.010 0.010 0.010 0.010 0.007

1kHz 0.019 0.005 0.019 0.006

10 kHz 0.026 0.012 0.026 0.018

100 kHz 0.024 0.010 0.030 0.020

1 MHz 0.018 0.008 0.025 0.020 0.024 0.030 0.007

10 MHz 0.008 0.006 0.020 0.020

100 MHz 0.007 0.006 0.010 0.010

1 GHz 0.006 0.002 0.008 0.008 0.009

2 GHz 0.006

Table 3.4.3 · Dielectric Loss Tangent, d,(Dissipation Factor)

Vectra®


38

Rela

vtiv

e Pe

rmitt

ivity

(Die

lect

ric C

onsta

nt)

6.0

0 10 MHz3.0

10 Hz 100 Hz 1 kHz 10 kHz 100 kHz 1 MHz

-190°C

3.5

4.0

4.5

5.0

5.5

100 MHz 1 GHz 10 GHz

-165°C

-113.5°C

-71.5°C

100°C

-10.7°C

150°C

200°C

75°C

24°C

6.96

250°C

Fig. 3.4.1 · Relative Permittivity (Dielectric Constant)

Vectra®


39

3

Die

lect

ric L

oss

Tang

ent (

Dis

sipa

tion

Fact

or)

0.1

0 10 MHz

0.01

010 Hz 100 Hz 1 kHz 10 kHz 100 kHz 1 MHz

-190°C

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

100 MHz 1 GHz 10 GHz

-165°C

-113.5°C

-71.5°C

100°C

-10.7°C

150°C

200°C

250°C

75°C

24°C

0.220.182(0.5 at 100 Hz)

Fig. 3.4.2 · Dielectric Loss Tangent (Dissipation Factor)

Vectra®


40

3.5 Regulatory Approvals

3.5.1 Military specification

Vectra A130, Vectra A150 and Vectra C130 are on theQualified Products List of products qualified undermilitary specification MIL-M-24519.

Vectra A130 Type GLCP - 30F Vectra C130 Type GLCP - 30F Vectra A150 Type GLCP - 50F

3.5.2 Food and Drug Administration

Many Vectra grades are listed under Drug Master FileDMF #8468 and Device Master File MAF #315:

Base resins Vectra A950Vectra B950Vectra C950

Glass reinforced Vectra A115Vectra A130/D-3Vectra A150Vectra B130Vectra B150Vectra C115Vectra C130Vectra C150Vectra E130iVectra L115/D-2Vectra L130/D-2Vectra L130XL

Carbon fiber Vectra A230Mineral filled Vectra A515

Vectra A530Mixed fillers Vectra A435

3.5.3 United States Pharmacopoeia

The following products meet United StatesPharmacopoeia (USP) Class VI requirements:

Base resins Vectra A950Vectra B950

Glass reinforced Vectra A130/D-3Vectra E130iD-2Vectra L130XL

Carbon fiber Vectra A230Mineral filled Vectra A515

Vectra A530

3.5.4 Biological Evaluation of Medical Devices (ISO 10993)

The following products are compliant with ISO 10993

Glass reinforced Vectra A130Mineral filled Vectra A530

3.5.5 Underwriters Laboratories

All commercially available Vectra LCP products canbe found listed in the Yellow Card by UL. Forspecific listings see Table 3.3.4 or contact your VectraLCP Technical Representative.

3.5.6 Canadian Standards Association

The Canadian Standards Association recognizes mostof the commercially available Vectra LCP products.For information on a specific grade, contact yourVectra LCP Technical Representative.

3.5.7 Water Approvals – Germany and Great Britain

In Germany, the following Vectra grades meet theKTW test procedure recommended by BGVV forcold (23°C) and hot (90°C) water use:

Glass reinforced Vectra A130Graphite modified Vectra A625

In Great Britain, the WRc has listed the followingVectra LCP grades under BS 6920 for use in cold andhot (85°C) water:

Glass reinforced Vectra A130Graphite modified Vectra A625

Vectra®


41

3

Vectra LCP has exceptionally low equilibrium moisture content (Table 3.0. short-term properties).

4. Environmental Effects

4.1 Hydrolysis

Vectra® LCP has exceptional resistance to hydrolysis,compared with other polyesters. Figures 4.1.1 throughFigure 4.1.4 show the results of immersion tests in hotwater and steam. Prolonged exposure at hightemperatures leads to gradual hydrolytic degradation.

Rete

ntio

n (%

)

100

Immersion Time (hours)0 500 1000

0

20

40

60

80

E530i

A130

L130

E130i

H130

Fig. 4.1.1 · Tensile strength versus immersion time in hot water

Rete

ntio

n (%

)

100


0

20

40

60

80E530i

A130

L130

H130

E130i

Fig. 4.1.2 · Tensile modulus versus immersion time in hot water

Rete

ntio

n (%

)

100


0

20

40

60

80

A130

E130i

H130

Fig. 4.1.3 · Tensile strength versus immersion time in steam

Rete

ntio

n (%

)

100


0

20

40

60

80

A130

H130

E130i

Fig. 4.1.4 · Tensile modulus versus immersion time in steam

4

Vectra®


42

Section 4.2 Chemicals and Solvents

Vectra LCP has good resistance to chemicals, partic-ularly organic solvents (even at high temperatures),cleaning agents normally used in the electronicsindustries and chemicals used for sterilization in thehealth care industry. The Vectra LCP resistance toconcentrated mineral acids and alkaline (both inor-ganic and organic) is highly problematic.

The resistance of Vectra LCP to methanol and methanol containing fuels depends very much on the temperature and the degree of contact. In applica-tions involving constant contact with methanolcontaining fuels, the temperature should not exceed70°C. The results of testing in various chemicals, solvents and fuels are given in Table 4.2.1. Injectionmolded test specimens were immersed in the mediumfor a given period of time without any externallyinduced stress. The additional effect of mechanicalstresses could alter the results. The data are for initialguidance only. Before commercial use the materialshould be tested using the identical processing andexposure conditions expected in actual use. Changes in concentration, temperature of exposure or the addition of additives can significantly affect the results.

Five bars, 127 mm x 12.7 mm x 3.2 mm, were im-mersed in the medium without external stresses.Changes in weight, and dimensions, flexural strength,flexural modulus and hardness were measured.

Table 4.2.1 · Chemical Resistance

Rating: + Resistant – less than 2% change in weight and dimension, less than 5% change in mechanical properties.

o Limited resistance– Not resistant

Medium Conditions Vectra LCP Rating(time/temperature) grade

Acetic acid (glacial) 30 days/118°C A950 +20 days/23°C A625 +

Acetic acid (100%) 30 days/118°C A950 +

Acetone 180 days/56°C A950 +A130 +A625 +

Acetonitrile 120 days/23°C A625 +

Brake fluid 30 days/121°C A130 o(Castrol® TLX 988C) A420 o

A422 oA950 +B950 +C950 +

90 days/121°C A130 –A420 –A422 –

Brake fluid 90 days/121°C A130 o(NAPA® brand DOT-3) A420 o

A422 o

Caustic soda solution (5%) 90 days/23°C A130 +A625 +

180 days/23°C A950 +A130 oA625 oA515 +

30 days/70°C A950 +180 days/70°C A950 o

A130 –A625 –A515 –

Caustic soda solution (10%) 180 days/23°C A950 +A130 +A625 oA515 +

30 days/88°C A950 oA130 –C950 +

Caustic soda solution (30%) 30 days/88°C A950 –A130 –A625 –C950 –

Chlorine gas 180 days/23°C A950 +A130 +A625 +

Chlorine/water 180 days/23°C A950 +(saturated solution) A130 +

A625 +

Chromic acid (50%) 90 days/50°C A625 +180 days/50°C A950 +

A130 oA625 o

30 days/70°C A950 +A130 +

60 days/70°C A950 +A130 o

Vectra®


43

4


Chromic acid (70%) 30 days/88°C A950 +A130 oA625 o

Dimethyl formamide 180 days/66°C A950 +A130 +A625 +

Diphenylamine 180 days/66°C A950 +A130 +A625 +

Diphenyl carbonate 10 days/250°C A950 –

Engine oil, 10W-30 30 days/121°C A950 +B950 +C950 +A130 +C130 +

Ethanol 30 days/52°C A950 +

Ethyl acetate 180 days/77°C A950 +A130 +A625 +

Ethylene diamine 30 days/100°C A950 –180 days/23°C A950 +

A130 oA625 +

Ethylene glycol (50/50) 30 days/50°C A950 +30 days/121°C A950 o

B950 oC950 oA422 –A150 –

Fluorinert® FC-70 1 day/215°C A950 +A130 +C130 +

Formic acid (80%) 30 days/104°C A950 +A625 +

270 days/104°C A950 oA625 o

455 days/104°C A950 –

Fuels:

Fuel C (ASTM D471) 30 days/121°C A950 +50/50 iso-octane/toluene B950 +

C950 +90 days/121°C A130 o

A422 o

Fuel C + 20% methanol 125 days/60°C A130 +A230 o

Fuel C + 20% ethanol 125 days/60°C A130 +A230 o

M-85 fuel 20 days/121°C A130 –A422 –

Lead free gasoline (petrol) 30 days/121°C A950 +B950 +

90 days/121°C A130 +A422 +

Lead free gasoline 30 days/121°C A950 o(petrol) + 10% methanol B950 o

90 days/121°C A130 –A422 –

90 days/93°C A130 oA422 oA625 +


Gasoline (petrol) 30 days/121°C A950 +w/70/30 heptane/toluene, B950 +copper ion, t-butyl-hydro-peroxide

H-FCKW 123 10 days/50°C A130 +(1)

C130 +(1)

A530 +(1)

C150 +(1)

C810 +(1)

Hexafluoro-isopropanol 10 days/25°C A950 –

Hexane 10 days/23°C A625 +

Hostinert® 216/175/130 1 hour A130 +(1)

C130 +(1)

C150 +(1)

C810 +(1)

Hydrochloric acid (37%) 30 days/88°C A950 +A130 oA625 oC950 +

120 days/88°C A950 oA130 oA625 o

Hydrofluoric acid 30 days/23°C A950 –(anhydrous)

Hydrogen chloride 30 days/23°C A950 –(anhydrous)

Iso-octane 14 days/60°C A625 +A422 +

120 days/23°C A625 +

Methanol 30 days/64°C A950 +B950 +

90 days/64°C A130 +A422 o

45 days/110°C A130 –

Methylene chloride 180 days/40°C A950 +A130 oA625 +

Monochloroacetic acid 180 days/50°C A950 +A130 +A625 +

Morpholine 10 days/132°C A130 +(200ppm/steam) (tetrahydrooxazine)

Nitric acid (50%) 120 days/23°C A625 +60 days/70°C A950 +

A130 +A625 +

Nitric acid (50%) 180 days/70°C A950 +A130 oA625 +

Nitric acid (70%) 30 days/88°C A950 oA130 –A625 o

Nitrobenzene 30 days/66°C A950 +

Nitroglycerine 30 days/66°C A950 +

Oil – shock absorber 40 days/150°C A130 +(Shell® GHB 15)

Oil – silicone 30 days/200°C A950 +

Table 4.2.1 · Chemical Resistance (continued) Table 4.2.1 · Chemical Resistance (continued)

Vectra®


44

Section 4.3 Permeability

Vectra LCP has extremely low permeability to watervapor, oxygen and other gases. Figure 4.3.1 shows thesuperior performance of unfilled Vectra LCPpolymers compared to conventional barrier materialssuch as ethylene vinyl alcohol copolymer (EVOH),polyvinylidene chloride (PVDC) and MXD6 (a co-polyamide of meta-xylenediamine and adipic acid).Because of its greater impermeability, Vectra LCPfilms present the opportunity to use thinner barrierlayers in coextruded structures. In the production ofmonolayer LCP film, the problems of fibrillation andproperty imbalances can be addressed through post-extrusion techniques such as biaxial orientation.

The oxygen permeability of films made from VectraA950 is compared to other barrier materials in Table4.3.1. Moisture vapor transmission is compared inTable 4.3.2.

Section 4.4 Radiation resistance

Vectra LCP has excellent resistance to gamma radiation. Table 4.4.1 shows the effect of Cobalt 60radiation on mechanical properties of Vectra A950.


Oil – hydraulic (Skydrol®) 30 days/71°C A950 +B950 +

Oil - transmission 30 days/149°C A422 +(Dexron® II) A625 +

A420 +B420 oC950 +C130 +

90 days/149°C A420 oA422 oA625 +B420 oC130 +

Pentafluorophenol 10 days/60°C A950 –

Phenol 100 days/100°C A950 +A130 oA625 +

Refrigerant R-22 30 days/80°C A950 +A625 +

Refrigerant R-12 60 days/100°C A625 ++ 5% refrigerator oil

Refrigerant 113 180 days/47°C A950 +A130 +A625 +

Refrigerant 113 TR-T 30 days/23°C C130 +C810 +

Refrigerant 113 TR-P 30 days/23°C C130 +(F113 + 35% isopropanol) C810 +

Refrigerant 113 TR-E35 30 days/23°C C130 +(F113 + 35% ethanol) C810 +

Refrigerant R134A 60 days/100°C A625 ++ 5% refrigerator oil

Sodium hydroxide (5%) 90 days/23°C A950 +A130 +

30 days/70°C A950 +A130 o

60 days/70°C A950 oA130 o

Sodium hydroxide (10%) 90 days/23°C A950 +A130 +

30 days/88°C A950 oA130 –

Sodium hydroxide (30%) 30 days/88°C A950 –A130 –

Sodium hypochlorite 28 days/23°C A130 o(12.5%) 28 days/70°C A130 –

Sulphuric acid (50%) 180 days/88°C A950 +A130 +A625 +

Sulphuric acid (70%) 5 days/190°C A950 –A130 –A625 –C950 –

Sulphuric acid (93%) 8 days/23°C A950 oA515 oA625 oB950 –

30 days/121°C A950 –A130 –A625 –A950 –


Tetrahydrofuran 120 days/23°C A625 +

Toluene 180 days/111°C A950 +A130 +A625 +

Trichlorethane 90 days/66°C A950 +

Urea (46%) 60 days/88°C A950 oA130 –A625 o

Water 10 days/121°C A950 +40 days/121°C A950 o

A625 +60 days/121°C A950 o

A130 o

Water vapor 70 days/121°C A950 oA130 oA625 +

(1) Weight change in 60 x 60 x 4 mm plaques only

Castrol® TLX is a registered trademark of Castrol Limited.NAPA® is a registered trademark of National Automotive Parts Association.SKYDROL® is a registered trademark of Monsanto Co.DEXRON® is a registered trademark of General Motor Corp.Fluorinert® is a registered trademark of Minnesota Mining andManufacturing Co.Hostinert® is a registered trademark of Hoechst AG.Shell® is a registered trademark of Shell Oil Co.

Table 4.2.1 · Chemical Resistance (continued) Table 4.2.1 · Chemical Resistance (continued)

Vectra®


45

4

Wat

er V

apor

Tra

nsm

issi

on R

ate

(g·m

m/m

2 ·da

y)

100

Oxygen Permeability (cm3·mm/m2·day·atm)0.001 0.1 1000

0.001

0.01

0.1

10

0.01 10

EVOH

MXD6

Nylon 6

PET

1

1

HDPEPCTFE

A950B950

PVDC

L950LKX1107

PAN

OPP

Data source: Permeability andOther Film PropertiesPlastics Design Library, 1995

Fig. 4.3.1 · Permeability of various polymer films(A950, B950, L950, LKX1107

are Vectra LCP grades)

Section 4.5 Ultraviolet and weathering resistance

Vectra LCP, like other plastics, shows a surface change over the course of time on exposure to weathering. Typically, the exposure to ultraviolet(UV) radiation causes a white deposit of degradedmaterial to form on the surface with consequent lossof gloss and color change. This phenomenon iscommonly referred to as chalking.

After artificial weathering for 2,000 hours, samplesmolded from Vectra LCP retained over 90% of theirinitial mechanical property values (Table 4.5.1). Afterone year of outdoor weathering a slight white depositwas detected.

Table 4.4.1 · Cobalt 60 radiationVectra A950 (Per cent retention of properties)

Table 4.5.1 · Results of artificial weathering for 2,000 hours

(ASTM D2565 – xenon arc lamp, air temperature 125°C,

water spray for 18 minutes every 202 minutes)(Per cent retention of properties)

Table 4.3.1 · Oxygen permeability(cm3·mm/m2·day·atm)

Temperature = 23°C, Relative Humidity = 0%

Vectra A950 0.014

Vectra B950 0.006

Vectra L950 0.041

Vectra LKX1107 0.016

Vectra RD802 0.019

EVOH 0.003 to 0.050

PVDC 0.035

MXD6 0.070

PET 2.3

HDPE 55

Nylon 6 1.3

PCTFE 5.7

Vectra A950 0.0054

Vectra B950 0.0034

Vectra L950 0.014

Vectra LKX1107 0.010

Vectra RD802 0.0054

EVOH 0.50 to 2.2

PVDC 0.10

MXD6 1.3

PET 0.01 to 0.02

HDPE 0.10 to 0.14

Nylon 6 5.6 to 10

PCTFE 0.010 to 0.020

Table 4.3.2 · Water vapor transmission(gm·mm/m2·day)

Temperature = 23°C, Relative Humidity = 100%

Radiation Dose 250 1,000 2,500 5,000 Mrads Mrads Mrads Mrads

Tensile strength(1) 97 95 95 95

Tensile modulus(1) 100 100 106 106

Break elongation(1) 81 81 79 79

Flexural strength(2) 101 102 102 102

Flexural modulus(2) 108 108 116 125

HDT @ 1.82 MPa(3) 100 100 100 94

(1) ASTM D638 (2) ASTM D790 (3) ASTM D648

Vectra A950 Vectra A130

Tensile strength(1) 95 95

Tensile modulus(1) 90 98

Flexural strength(2) 95 95

Flexural modulus(2) 95 95

HDT @ 1.82 MPa(3) 90 92

Notched Izod(4) 90 95

(1) ASTM D638 (2) ASTM D790 (3) ASTM D648 (4) ASTM D256

Vectra®


46

Material Safety Data Sheets (MSDS) are available forall Vectra LCP grades. Always consult the MSDSbefore working with any Vectra LCP.

5.1.1 Start up and shut down procedures

Starting up an empty machine or one previously filled with Vectra LCP

The cylinder temperatures are set to the levelrequired for processing. When the set values havebeen reached, it is advisable to wait for 5 minutesbefore filling the plasticizing cylinder. When thecylinder has been filled, several shots are ejected intothe open (air shot). Special attention should be givento the nozzle temperature because if it is too cold themelt will freeze and block the nozzle. When thetemperature of the melt ejected into the open hasbeen checked with a needle pyrometer and the melt isflowing perfectly, processing can start.

Short and long interruptions to the molding cycle

For interruptions up to one half-hour no special measures are required. For longer interruptions thetemperature settings should be reduced to below260°C after purging the melt from the cylinder.

Changing from another thermoplastic to Vectra LCP

Since many other plastics are less thermally stable atthe processing temperatures used for Vectra LCP, it isadvisable to purge them from the machinebeforehand as thoroughly as possible. A suitablepurging material is a low melt index polypropylene(glass fiber reinforced grades have a better cleaningeffect). The purging material is purged into the openat about 250°C until it runs clean. Before increasingthe cylinder temperatures to run Vectra LCP be surethat the purge material is completely out of themachine. When the set temperatures are reached, runthe Vectra LCP with the unit disconnected from themold until the melt is free of all traces of the purgematerial.

Changing from one Vectra LCP grade to another

It is possible to process different Vectra LCP gradesusing one grade to remove another without purgingwith another polymer in between. For this purpose,

5. Processing

Vectra® LCP can be processed using commoninjection molding and extrusion techniques. Mostfrequently however Vectra LCP is injection molded.Fast cycles, conventional processing and thepossibility of blending with up to 50% regrind makefor high cost effectiveness. Because of the material’sgood flow properties and low tendency to form flash,long, thin-walled parts can be produced.

5.1 Safety considerations

No particular hazards have been identified whenprocessing Vectra LCP provided standard industrysafety practices are observed. Vectra LCP products areinherently stable materials. If heated to excessivelyhigh temperatures however they can decompose andgive off decomposition products, as will most otherthermoplastics. If insufficient ventilation is available,concentrations of these decomposition products canbuild up and may be harmful to health. A suitableventilation system is therefore required.

To prevent thermal decomposition, off gassing andpressure buildup in the cylinder, melt temperaturesshould not exceed 350°C for lower melt pointproducts, i.e. Vectra A-series, B-series and L-Series, or360°C for the higher melt point products, e.g. VectraC-series, Ei-series or H-series. These temperatures arewell above the normal processing range. The meltshould not remain above 340°C for more than 1/2 hourfor the lower melt point materials, or above 350°C formore than 1/2 hour for the higher melt point products.This readily permits temporary machine stoppage for process adjustments. For more extendedshutdowns run the screw dry. Do not process withthese residence times and temperatures. See Section6.2 for recommended processing conditions.

Other important precautions:

- Sufficient time should be allowed to heat up themachine. The cylinder should have reached therequired processing temperature settings 5 minutesbefore feeding in the pellets and turning the screw.

- When handling hot material and molds, gloves, protective clothing and goggles should be worn.

- When switching off the machine, the injection unitshould be retracted to avoid nozzle freezing bycontact with the mold.

Vectra®


47

5

the first material is completely pumped out and thendisplaced by the second material. In case of a colorchange (particularly from black to natural), nopurging is necessary, but allow enough time to pushall of the black out of the machine.

Shutting down the machine

If Vectra LCP is to be processed again after themachine has been shut down, the injection unit mustsimply be run until empty. Then the nozzle andcylinder heaters can be switched off.

If a change to another thermoplastic is planned, theVectra LCP must first be purged with high-densitypolyethylene or polypropylene. The temperaturesshould remain set at Vectra LCP processingtemperatures because if they are reduced prematurelytraces of Vectra LCP can no longer be purged out.

5.1.2 Fire precautions

Vectra LCP is inherently flame retardant.Nevertheless it is in the interest of the converter whenstoring, processing or fabricating plastics to take thenecessary fire precaution measures. Particular careshould be taken to observe specific regulations inindividual countries.

Certain end products and fields of application mayimpose special requirements from the fire preventionstandpoint. It is the responsibility of the raw materialconverter to ascertain and observe such requirements.

5.2 Drying and storage

Vectra LCP resins are well known for their excellentthermal and hydrolytic stability. To ensure theseproperties are optimized, the resin should be driedcorrectly prior to processing. If the resin is not properly dried, residual moisture can cause voids,splay, imperfections and in extreme cases polymerdegradation. These effects have the potential for poorpart quality. Therefore, it is important that the material be dried using the recommendedconditions and appropriate equipment.

To ensure the quality of molded parts, a desiccantdryer with two or more desiccant beds is stronglyrecommended. Multiple desiccant bed dryers allowdrier air to be delivered to the plastic resin than single

bed dryers do, thus, reducing both moisture contentand necessary drying time.

It is also recommended that the material be allowed toreach the recommended drying temperature before thedrying time is started. When a resin is placed in ahopper at room temperature, it may take 2 to 6 hoursfor the material to reach the necessary dryingtemperature. This time will vary according to thethermal properties of the resin, the mass of materialbeing dried and the capability of the hopper.

In addition, it is important to note the location of thethermocouple that measures the temperature of the airbeing delivered to the hopper. Dryer systems that donot measure the air temperature at the inlet of thehopper might not accurately represent the delivery airtemperature. This is because significant heat loss canoccur between the exit of the dryer unit and the inletof the hopper. Heat loss, even through insulatedtubes, can result in as much as a 50°C lowering indrying temperature.

Summary of Drying Recommendations

1. The resin inside the hopper should be allowed toreach the drying temperature, before the minimumdrying time is started.

2. A desiccant dryer with two or more desiccant bedscapable of reaching -40°C dew point or below isrecommended.

3. Ensure the delivery air temperature readoutrepresents the temperature of the air being deliveredto the hopper. If the thermocouple is located toofar from the hopper, or is not insulated, it might benecessary to raise the set temperature of the de-livery air. However, please check with the manu-facturer to determine the dryer’s temperature capabilities.

Series A, C, D, B Ei, L LKX1112

and V and H

Drying 150 150 150/170 90

temperature (°C)

Drying time 4-24 6-24 4-24/4-16 16-24

(hours)

Vectra®


48

6.1.3 Check Ring

Because Vectra LCP resins have such low viscosity, itis essential that the check ring non-return valve beworking correctly (Figure 6.1.2). The simplest way toensure that the check ring seats properly is to confirmthat it holds a constant 2 to 3 mm cushion.Malfunctioning check rings result in inconsistentparts, short shots and poorly formed weld lines.

6. Injection Molding

6.1 Equipment selection

Vectra® LCP processes much like any highly crystal-line thermoplastic using common injection moldingequipment.

6.1.1 General

Abrasive wear by glass on injection screws occursprimarily on the lands and edges of screw flights. In time, the root diameter will wear somewhat in the transition and metering zones. Screw should be of heat-treated and stress relieved alloy steel with ahard surface.

A minimum of three zone heating control of thecylinder is necessary for precise temperature control.

Despite the thermal stability of the melt, one shouldaim for the shortest possible melt residence time (lessthan 5 minutes) in the cylinder, i.e., the capacity of themachine should be matched to the shot weight of theinjection molding. The shot size ideally should be noless than 50 to 75% of the machine’s rated shotcapacity.

Since Vectra LCP is a fast cycling material the machine should have a high plasticating or meltingcapacity to achieve fast cycle times.

6.1.2 Screw Design

The design of the screw is not crucial for processingVectra LCP but some general rules should be observed (Figure 6.1.1):

A three-zone screw evenly divided into feed,compression and metering zones is preferred. A higher percentage of feed flights may be necessaryfor smaller machines.

Zone distribution:- 1/2 feed- 1/4 transition (compression)- 1/4 metering

Screw length/diameter ratio, L/D from 16:1 to 24:1

The preferred compression ratio ranges from 3:1 forlarger machines to as low as 2:1 for smaller machines.

ValveMeteringDepth

FeedDepth

OutsideDiameter

MeteringZone

Tran-sitionZone

FeedZone

ShankLengthFlight Length

Overall Length

Fig. 6.1.1 · Metering type screw recommended for processing Vectra LCP

A. Plastication

Check Ring Open

Check Ring Closed

B. Injection

Fig. 6.1.2 · Check ring non return valve used on reciprocating screw injection molding machines

Vectra®


49

6

6.1.4 Nozzle

Vectra LCP can be processed with a free flow or shutoff nozzle. In the case of free flow nozzles, those witha small aperture (11/2 to 21/2 mm) or nozzles such as areverse taper nozzle are recommended to preventdrooling of the melt. Nozzles should be as short aspossible and have a heating band with its owntemperature control system. If drooling or stringingoccur, the problem can normally be eliminated byreducing the nozzle temperature or reducing thenozzle diameter.

6.1.5 Hot runner systems

Vectra LCP can be processed successfully in hot runner systems to conserve material and reduce theamount of rework generated. Externally heated hotrunner systems are preferable to the internally heatedsystems for processing Vectra LCP. The externallyheated hot runner systems achieve an even flow ofmelted material with a constant melt temperature overthe cross-section of the hot runner. The heat energy isevenly distributed from outside to inside; this ensuresa homogeneous temperature distribution in the melt.Low voltage systems (5 or 24V) have been wellproven in practice. These systems ensure accuratecontrol and regulation of the heating power. The useof heating coils in these systems requires less spaceand can heat the nozzle tips.

The choice of the correct tool steel is important in the design of hot runner tools for processing VectraLCP (Rc > 56).

The hot runner system designer should also considerthe shearing of the material and the associated effecton viscosity. For this reason, the cross-sections of thehot runner for Vectra LCP should be designed assmall as possible. If we assume that a cross-section of 4 to 8 mm is typical for conventional plastics, then for Vectra LCP the cross section should be 2 to4 mm. In the same way as the hot runner, the hot runner nozzles and the gate should be given thesmallest possible dimensions. Nozzle cross-sectionsof up to 2 mm and gates from 0.3 to 0.8 mm havebeen found effective in practice (Figure 6.1.3).

Care should be taken to ensure that the meltedmaterial is not retained for too long in the hot runnerduring processing. If possible, the total residence timein the melt should be less than 5 minutes to minimizethe thermal stress on the material. It is important that,as the injection occurs, a constant

flux develops from the filling start. This is achieved by correct positioning of the gate, so that it injectsagainst a core or a wall. The creation of jetting should be avoided. Linking to the component can be achieved either by direct hot runner, or by a coldsub runner. The recommendations for Vectradistributor geometry apply to the small sub-distributor (Figure 6.1.4). All cavities should bedesigned in such a way that the flow resistanceremains constant. Because of the low viscosity, themelt can move ahead in regions of low flow resistance,possibly leading to warpage problems.

Parts manufactured from Vectra LCP with hot runner systems are typically small, thin-walled partsmainly for the electrical and electronics industries,where good temperature resistance is important forsoldering processes. To maximize temperature resist-ance of the molded part, the processing temperatureprofile should be kept as low as possible within therecommended processing range. Retention timesshould also be minimized.

Ø 3 mm

Ø 3 mm

Ø 2.5 mm

Ø 0.3 - 0.8 mm

Fig. 6.1.3 · Hot runner system

2-cavaties 4-cavaties

8-cavaties

Fig. 6.1.4 · Hot runner distributor

Vectra®


6.2 Injection molding processing conditions

Vectra LCP is notably easy to process. Typicalprocessing temperatures are summarized in Figure6.2.1. Recommendations for start up, shut down andmaterial changeovers are given in Section 5.1.1.

6.2.1 Melt temperature

Determine the melt temperature manually with aneedle pyrometer when the machine has been cyclingfor several minutes. If there are any deviations fromthe set value, the cylinder and nozzle heater settingsmust be adjusted accordingly. Melt temperatureshould generally be checked in this way because themelt thermocouples integrated into the injectionmolding machine do not usually show the true value.

If the molded parts are to be exposed to elevatedtemperatures above 215°C, e.g., electronic componentssubjected to vapor phase or infrared reflow soldering,then it is imperative that the material is not overheatedduring processing. The molder should maintain the melttemperature at or even below the temperaturesrecommended in Figure 6.2.1, and the melt residencetime in the cylinder should be minimized.

Fig. 6.2.1 · Typical injection molding conditions

6.2.2 Injection velocity

To improve weld line strength and flow use very fastinjection speeds (0.2 to 0.3 seconds fill time). Foroptimum mechanical performance the injectionvelocity should be moderate (0.4 to 0.6 seconds).Vectra LCP resins are shear thinning, i.e., their meltviscosity decreases quickly as shear rate increases. Forparts that are difficult to fill, the molder can increasethe injection velocity to improve melt flow. Increasingthe injection velocity can be more effective than rais-ing the melt temperature and is less likely to degradethe resin. If the gates are too small however, very fastinjection rates can induce excessive polymer shearheating and breakage of fibrous reinforcements. Anadditional gate may be more appropriate in this situ-ation to reduce shear.

6.2.3 Mold temperature

Vectra LCP can be processed over a wide range ofmold temperatures. Settings between roomtemperature and 180°C are possible with temperatures between 80°C to 120°C being the most common.Higher mold temperatures usually result in a smoother surface finish, improved flow and betterdimensional stability under heat (i.e. surface mounttechnology).

6.2.4 Screw speed

The screw speed should be sufficiently high to achieve complete plastication of the melt one to twoseconds before the mold is opened. Typical speeds are100 to 200 RPM at a screw diameter of 15 to 25 mm.

6.2.5 Backpressure

Backpressure is not normally necessary duringplastication and should be set to a minimum (2 to 3bars). With fiber reinforced grades, excessivebackpressure leads to fiber breakage.

6.2.6 Screw decompression

Screw decompression (suck back) is not generallyrecommended. If screw decompression is necessary toprevent drooling, it should be restricted to a minimum(2 to 4 mm). Excessive decompression can draw air ormoisture into the nozzle and result in a cold slug orblistering on the surface of the molded part.

TW1 TW2 TM

TN T4 T3 T2 T1 nS

TD

Processing Temperatures (°C)

Series A and B C and D Ei and H L V

T1 270-280 290-300 315-325 275-285 295-305

T2 275-285 300-310 320-330 285-295 300-310

T3 280-290 310-320 325-335 295-305 300-310

T4 285-295 320-330 330-340 305-315 300-310

TN 290-300 300-330 335-345 305-315 300-310

TM 285-295 320-340 335-345 300-320 300-315

TW1 80-120 80-120 80-120 80-120 80-120

TW2 80-120 80-120 80-120 80-120 80-120

nS – see screw speed, Section 6.2.4TD – see drying instructions, Section 5.2

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6.2.7 Injection pressure

The optimum injection pressure depends on thespecific Vectra LCP grade as well on the design of the molded part, the mold and machine conditions.All Vectra LCP grades have low melt viscosity andgenerally require lower injection pressures than otherthermoplastic materials.

6.2.8 Holding pressure

The holding pressure should be equal to or less thanthe injection pressure. The required holding pressuretimes are shorter than for partially crystallinethermoplastics since Vectra LCP freezes very quickly.The required holding pressure time can be determinedby weight optimization.

6.2.9 Cycle time

All Vectra LCP resins have, in addition to lowviscosity, a very low heat of fusion (about 5 to 10% ofthe heat of fusion of PET or PBT). This means thatrelatively little heat has to be removed from themolded part through the walls of the mold to freezethe part. Ejection can take place at high temperaturesif the ejectors are designed not to make an indentationon the molding. Very low internal stresses at all moldtemperatures enable the injection mold to be operatedat low temperatures. These characteristics lead toexceptionally fast cycle times. As the wall thickness ischanged, the cooling time varies approximately withthe square of the thickness. This impacts the totalcycle time.

6.3 Regrind

The regrinding procedures for Vectra LCP are similarto those of other high modulus thermoplastics. LCPare tough, fibrous materials that require some care inhandling to produce adequate regrind chip quality.High quality regrind will improve the feedingcharacteristics of the regrind and virgin mix, thestability of the molding process and ultimately part performance.

Several variables will affect the regrind quality. Theseinclude the particular grade of Vectra LCP beingprocessed, the type of filler or reinforcement, thegeometry of the part (or runner), the percentage ofregrind, the type of delivery system and machine.

The processor and end user must determine the upperlimit of regrind by evaluating part performance andregulatory limits as well as molding process stability.

The following guidelines will produce the bestpossible regrind.

6.3.1 General recommendations

1. Runners, sprues and scrap parts will cut best, andshatter least, when fed to the granulator while stillhot, i.e. just out of the mold. Granulating while hotwill produce the smoothest chip edges and generatethe least amount of tails and fines. If this is notpractical, the scrap may be reheated in an oven toapproximately 150°C and then cut while hot. Whengrinding, take care to feed the parts into thegranulator slowly. This will minimize the residencetime in the granulator and encourage cutting ratherthan smashing the scrap.

2. Select the largest hole size in the granulator screen tocut scrap into a chip size that will feed into themolding machine being used. Different size machinesmay require different screens. A proper screen holesize ensures a minimum amount of “shredding” andfines generation as parts are being cut.

3. Sharp blades improve regrind quality. They willtend to cut rather than shatter the scrap.

4. Minimal gaps between blade and bed knife improveregrind quality. Set to the closest gap recommendedby the granulator manufacturer.

If the above procedures do not produce acceptableregrind with your existing granulators, you may haveto use a low speed granulator. Machines that operatebelow 30 RPM tend to improve chip quality by shearcutting the larger oversized granules during regrindingrather than smashing or shredding them. High speedgranulators tend to shatter the scrap rather thanshearing it – especially when it is cold, <100°C. Thisresults in Vectra LCP regrind that is rough andfibrous with a high level of fines.

The following chart indicates the approximatepercentage by weight of fines generated and chipquality of parts evaluated in one test. Naturally resultswill vary with equipment used and parts granulated.Fines are particles that pass through a 10-mesh screen.Excessive fines and poor chip quality may causedifficulty in feeding regrind into a molding machine.

Cut Hot Cut Cold

Low Speed Granulator Fines, weight % 5 13Chip Quality Good Fair

High Speed Granulator Fines, weight % 5 17Chip Quality Fair Poor

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6.3.2 Equipment

A number of users have reported success using an S-Cutter from Nissui Corporation for regrindingVectra LCP runners, sprues and parts. Nissui Corpo-ration can be reached at 3510 West Road, E. Lansing,MI 48823, phone number 517-332-7400, fax phone517-332-2148 or www.nissui.com. The equipment isavailable in Europe from Scholz Apparate &Anlagenbau GmbH, In der Hernau 5, D-90518Altdorf, Germany, phone number +49/(0)9187-4037,fax number +49/(0)9187-42548.

6.3.3 Using regrind

Four factors have the potential to cause loss ofproperties in regrind material: contamination, thermaldecomposition, hydrolysis (reaction with water) anddamage to reinforcements, especially glass fibers.

Vectra LCP resins have excellent thermal andhydrolytic stability when molded and dried at recom-mended conditions. Fiberglass reinforced productsmay exhibit some loss of notched Izod impact per-formance due to breakup of the glass fibers.

To maintain color uniformity and optimummechanical properties, limit regrind to 25%.Underwriters’ Laboratories accepts up to 25% regrindfor UL listed applications without added testing.

A mixture of 50% regrind is often acceptable for themajority of Vectra LCP materials. These productshave a UL listing for the use of 50% regrind (Table 3.3.4).

Whenever using regrind material, the end user musttest the finished parts to ensure satisfactoryperformance. Best practices for using regrind include:

1. Adequately dry both the regrind and repelletizedmaterial and the virgin resin, preferably to less than0.02% moisture. Refer to Section 5.2 forrecommended drying procedures.

2. Regrind material must be free from contaminationof any foreign material, including other plastics,metal, even other LCP resins.

3. Avoid excessive melt temperatures. 4. Maintain the melt residence time as short as

possible, preferably less than five minutes.5. Do not use screw decompression.6. Refer to Section 6.2 for recommended injection

molding conditions.

When molded using the above conditions, Vectra LCPmaintains about 80-100% of its strength and modulus.Glass fiber reinforced grades may exhibit a reductionin notched Izod impact due to fiber breakage duringprocessing. After repeated moldings, a slightdarkening of color has been observed.

Whenever regrind is used, and especially if a molderconsiders using greater than 25%, adhere to the following guidelines:

1. Run parts for qualification testing under steadystate conditions. Be in continuous production witha constant feed of regrind material at the desiredratio for several hours to establish the distributionof residence time.

2. Qualify the parts by the same process used for theoriginal qualification of virgin material.

3. Adhere to any regulatory requirements such as UL,Mil Spec, etc.

6.4 Troubleshooting

Many processing problems are caused by easilycorrected conditions such as inadequate drying,incorrect temperatures or pressures, etc. Oftensolutions can be found by following therecommendations given below.

Adjustments should be moderate and made a step at atime giving the machine time to stabilize before fur-ther adjustments are made. Check that the machine isoperating within the parameters recommended for thespecific grade of Vectra LCP. For example, melttemperature should be confirmed on air shots collect-ed at typical cycle times.

6.4.1 Brittleness

- Check for contamination- Decrease amount of regrind in the feed- Decrease melt temperature by

- Eliminating back pressure- Decreasing screw speed- Decreasing the cylinder temperature

- Dry the resin and regrind before use

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6.4.6 Jetting

Vectra LCP are highly oriented, exhibit little or no dieswell and tend to jet into large cavities.

- Decrease injection rate- Increase gate dimensions to 85 to 100% of

wall thickness- Improve gating so melt impinges on core,

pin or wall

6.4.7 Leaking check ring

- Vectra LCP has very low melt viscosity so the check ring must seal properly.

- Ensure that the check ring holds a 11/2 to 3 mm cushion

6.4.8 Nozzle problems

A. Nozzle drool or stringing

- Decrease nozzle temperature- Decrease melt temperature by

- Eliminating back pressure- Decreasing the screw speed- Decreasing the cylinder temperature

- Add minimal decompression (too much can causeblisters on reheating molded parts)

- Decrease mold open time- Dry the material thoroughly- Use a nozzle with a smaller orifice- Use a nozzle with a reverse taper- Use a nozzle with a positive shutoff

B. Nozzle freeze off

- Increase nozzle temperature- Decrease cycle time- Increase mold temperature- Add sprue break (carriage back) if available- Use a nozzle with a larger orifice

6.4.2 Burn marks

Vectra LCP products are highly oriented and normally appear darker around the gate.

- Check for contamination of resin feed- Decrease injection rate- Improve venting to minimize trapped gas- Increase gate size or relocate to improve venting

6.4.3 Dimensional variability

- Confirm complete screw recovery in allotted time- Confirm that check ring seats uniformly- Maintain a 11/2 to 3 mm cushion- Fill the mold as rapidly as possible- Increase cooling time- Check the machines hydraulic and electrical systems

for erratic performance- Reduce the number of cavities in the mold- Balance the layout of runners, gates and cavity- Improve venting- Increase the gate size

6.4.4 Discoloration

- Check for contamination of resin feed- Purge heating cylinder- Decrease melt temperature by


- Minimize residence time and cycle time- Improve venting in the mold- Minimize residence time by moving mold to a

press with a smaller shot size

6.4.5 Flashing

- Decrease injection pressure- Decrease feed or shot size to ensure a

11/2 to 3 mm cushion- Decrease injection rate- Decrease melt temperature by


- Check mold closure for mismatch of parting line- Improve mold venting- Increase gate size- Check press platens and mold support for

parallelism- Move mold to a larger clamp tonnage press

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6.4.9 Short shots

- Check hopper to confirm adequate feed- Ensure check ring is seated- Increase feed or shot size to ensure

11/2 to 3 mm cushion- Increase injection pressure moderately- Increase injection speed- Increase injection forward time- Increase mold temperature- Check cavity vents for blockage- Decrease size of gate (possibly runner) to

increase shear- Add additional smaller gates (Section 6.2.2)

6.4.10 Sinks and voids

Vectra LCP exhibits very low shrinkage and thus few sinks or voids. Most often, it is an indication ofshort shots.

- Ensure check ring is seated- Increase feed or shot size to ensure

11/2 to 3 mm cushion- Increase primary pressure time- For voids

- Increase mold temperature- Increase melt temperature

- For sink marks, decrease mold temperature- Check cavity vents for blockage- Relocate gates near the heavy sections- Core out the part

6.4.11 Sticking

A. Sticking in cavity

- Decrease primary pressure- Decrease injection speed- Decrease feed or shot size to ensure

11/2 to 3 mm cushion- Eliminate secondary pressure- Decrease primary pressure time- Eliminate undercuts; Increase draft- Check part for drag marks or unbalanced ejection- Polish tool in ejection direction- Improve effectiveness and balance of pullers and

sucker pins

B. Sticking on the core

- Measure core temperature, decrease temperature or improve cooling

- Eliminate undercuts- Polish cores- Increase drafts

C. Sticking in the sprue bushing

- Check the alignment and orifice size of the nozzlerelative to the sprue bushing

- Eliminate secondary pressure- Decrease primary pressure time- Increase mold close time- Add sprue break (carriage back) if available- Eliminate undercuts and polish surfaces of sprue

bushing- Provide a more effective sprue puller

6.4.12 Surface marks and blisters

Vectra LCP is highly oriented and often exhibits flowlines that are not splay marks.

- Check for contamination- Dry material before molding- Eliminate screw decompression- Decrease melt temperature by


- Decrease melt residence time by- Decreasing overall cycle time- Moving tool to a smaller capacity press

- Increase gate size

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6.4.13 Warpage and part distortion

Vectra LCP products are highly oriented and shrinkmuch less in the flow direction than in the directiontransverse to flow. Most warpage is due to the flowpatterns, dictated by part and gate design. Except formold temperature, processing conditions have littleeffect on shrinkage differential.

- Check for contamination- Confirm that the part ejects uniformly- Check for proper handling and immediate degating

of parts after ejection- Decrease mold temperature- Increase mold close time- Ensure that the part is properly packed by

- Confirming that the check ring holds a 11/2 to 3 mm cushion

- Increasing the primary pressure, injection rate or time

- Minimize molded in stress by decreasing - Injection pressure- Injection rate or time

- Try differential mold temperatures to counteract warp

- Relocate gate or adjust wall thickness’ to improve fillpattern

- Fixture the part to cool uniformly- Fixture the part, heat to near the melt then cool

the fixture

6.4.14 Weld lines

- Eliminate mold release- Increase injection speed- Increase injection pressure- Increase injection forward time- Increase mold temperature- Increase melt temperature- Vent cavity in weldline area- Provide overflow well adjacent to weld line area- Improve gating by

- Using a single gate- Increasing gate size

- Improve flow pattern by- Relocating gate- Making sure wall thickness is uniform- Adjusting wall thickness variations to direct

the melt flow

Vectra®


possible to produce films ranging from highlyanisotropic to fully isotropic in physical properties.Tensile modulus can range from 20,000 MPa/3,500MPa (MD/TD) for an anisotropic cast film to 7,000MPa/7,000 MPa for an isotropic blown film. Thiscapability is especially useful in the electronics indus-try where precise dimensional characteristics includinglow shrinkage and controllable CTE are required.

Mineral and fiber reinforced Vectra LCP can be usedfor extrusion as long as the die cross section is largeenough to accommodate the filler. Filled resins arerecommended for thermoformed sheet and for anextruded shape that is to be machined. Fillers can alsoimprove thermal and wear characteristics.

Be sure to follow the drying procedures outlined inSection 5.2 before processing Vectra LCP.

7. Extrusion

A number of unreinforced Vectra® LCP polymers are suitable for extrusion of rod, profile, film andsheet, pipe, tubing, fiber and extrusion blow moldinginto shaped articles. Table 7.0 lists selected injection molded properties of unreinforced Vectra LCP grades that are suitable for extrusion.

Extruded products are historically highly anisotropicand are very strong in the machine direction. Newprocessing techniques have been developed to im-prove the transverse direction properties and providea more isotropic shaped article.

Blown film processes can be utilized to reduce theanisotropy found in cast LCP films. The processtypically requires an unfilled Vectra LCP resin and islimited to a maximum film thickness in the range of100 microns. By adjusting the machine direction drawratio and transverse direction blow up ratio, it is

Table 7.0 · Vectra LCP grades suitable for extrusion

A950 B950 C950 E950i H950 L950 LKX1107 LKX1112

Thermal Transitions, °C

Tsolid-nematic (Tm, DSC peak) 282 279 325 340 330 305 220 212

Tnematic-solid (Tc, DSC onset) 236 226 278 288 285 256 170 177

Tg (DMTA, peak tan d) 113 147 113 125 125 134 126 135

DTUL, °C

@ 1.8 MPa 185 200 175 235 280 200 120 150

@ 8.0 MPa 95 130 90 155 200 125 100 105

Tensile Properties

Strength, MPa 180 150 140 140 140 140 110 140

Elongation, % 3 1 4 1 1 2 1 2

Modulus, MPa 10,600 19,800 7,800 12,600 17,200 11,400 11,000 11,500

Flex Properties

Strength, MPa (@ 3.5% strain) 160 140 150 140 160

Strength at Break, MPa 250 180 140

Strain at Break, % 2 2 2

Modulus, MPa 9,100 15,800 7,600 9,600 12,500 9,100 10,200 9,800

Impact Properties, kJ/m2

Izod, notched 95 40 20 75 75 70 35 75

Izod, unnotched 250 70 25 95 105 95 35 95

Charpy, notched 95 50 20 75 100 75 45 100

Charpy, unnotched 265 65 25 105 125 80 50 125

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7

7.1 Equipment selection

7.1.1 General

Vectra LCP should be extruded with a relatively cool feed zone, which increases throughput. A barrelL/D ratio of at least 30:1 is recommended to ensurecomplete and uniform melting of the polymer. Avacuum vented extruder barrel is helpful ineliminating volatiles in the extrudate.

7.1.2 Screw design

The melt viscosity of Vectra LCP is highly dependenton shear stress. This behavior commonly results in non-uniform melt flow, or surging. To minimize thisproblem, select a metering screw with deep flights in thefeed zone and a uniform square pitch. A compressionratio of 4:1 to 5:1 for a single stage screw or the firststage of a two-stage screw is preferred. For the secondstage of a vented screw, the compression ratio should be2:1 to 3:1. The length of any feed or metering sectionshould be at least five screw diameters with a gradualtransition between them.

7.1.3 Screen pack

Since Vectra LCP is often processed close to the melttemperature, efficient screen pack heaters and goodinsulation are essential to prevent polymer freeze up.A wide range of screen sizes (down to 100 mesh) canbe used for filtering the extrudate without causingexcessive pressure build up. A screen filter should notbe used when extruding filled polymer.

7.1.4 Head and die

Standard dies are generally appropriate for VectraLCP extrusion. Temperature control over the entirehead and die area must be uniform. The melt pressureshould be monitored and maintained as uniformly aspossible, and the screen pack replaced when thepressure starts to increase significantly.

7.1.5 Melt pumps

Because Vectra LCP is a shear thinning material, itexperiences a higher level of backflow over the screwflights than conventional polymers. This can result inreduced screw pumping efficiency at high extruderdischarge pressure. A melt pump is recommended forhigh extrusion rates and whenever a filter (cartridge orscreen changer) is utilized. The melt pump should beplaced directly downstream of the extruder.

7.2 Processing

Safety precautions, start up, and shut downprocedures for extrusion are very similar to thoseoutlined for injection molding in Section 5.1. Dryingand storage of material is described in Section 5.2.

7.2.1 Film and sheet

Extrusion of film and sheet can be carried out witheither unfilled or filled Vectra LCP polymer.Thermoforming operations generally require a glass or mineral filled grade, which can be used to extrudethicker gage sheet.

Film and sheet is often extruded close to the meltpoint so care should be taken against polymer freezeup in the screen pack and die, especially at start up.Thermally insulating these components is helpful.Extrusion temperatures can be carefully lowered fromthe recommended values for thicker sheet (greaterthan 0.25 mm) if necessary to maintain melt strength.

The distance from the die to the finishing roll nipshould generally be kept as short as possible to avoidpremature freezing of the molten extrudate. Adrawdown ratio (ratio of the die gap to film thickness)of 2.0 is recommended for thin film (less than 0.25mm), and a drawdown ration of 1.1 to 1.2 should beused for thicker film and sheet.

Standard center feed dies can be used to extrude filmand sheet. A large manifold is recommended to dis-tribute the melt evenly across the die. The die gap setting should be adjustable to help regulate the diepressure and achieve the desired drawdown ratio.

Film up to 0.25 mm thickness can be cast on a singleroll or extruded onto a three-roll stack. Thicker sheetmay require a straight through string up. Finishingrolls should be heated, if possible, to provide acontrolled uniform cooling rate and to produce a highquality film surface. Since Vectra LCP films neck inless at the edges that other plastics, the required widthof the finishing rolls for a given die size may begreater than expected based on previous experience.Film less than 0.25 mm thick may be wound on aspool, while thicker film generally must be cut into lengths.

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7.2.2 Profiles

Monofilament strands, rods and other profiles can beextruded from unfilled Vectra LCP resins, preferablyVectra A950 or Vectra B950. High molecularorientation developed during extrusion gives theseproducts exceptional tensile strength and stiffness inthe machine direction. Due to their high meltstrength, both products can be extruded eitherhorizontally or vertically. A die melt temperature ofapproximately 280°C to 285°C is suggested for VectraA950, and 300°C to 305°C for Vectra B950. Keep thedie pressure above 0.7 MPa to maintain a consistentdensely packed product.

Unlike many engineering thermoplastics, Vectra LCP products exhibit very little die swell or distor-tion upon exiting the die. With the proper die design,minimal drawdown is required to achieve highmechanical strength. A drawdown ratio of 4 to 7(ratio of die orifice area to cross sectional area ofextrudate) is recommended for best results.

The entry to the die orifice should be streamlined andfree of stagnation points so that polymer does nothang up and degrade. Conical entry dies with a 30 to70° cone entry angle are recommended for extrusionof circular cross sections. A die with no land length ispreferred but a short land length is acceptable. Keepthe die land length to no more than 4 times the orificediameter. A longer length will cause excessive sheardeformation and reduction of tensile properties. A conical die mandrel is generally used with its tipcentered upstream from the orifice entry.

Cooling and sizing of the extruded profile depends onthe cross sectional area. Air-cooling is adequate forthin strands up to 0.15 mm diameter. A sizing guideshould be used for any diameter greater than 3 mm.

Larger diameters and shapes should generally bewater-cooled. Water baths should be temperaturecontrolled and held at 45°C for small diameter profiles(for example, 2 mm diameter rod running at 30 m/minute line speed). A short (approximately onemeter) bath length is generally sufficient. The distancebetween the die face and the water bath normallyranges from less than 1 meter to 3 meters and may beadjusted to achieve the most circular cross sectionpossible for the extruded monofilament.

Due to the stiffness of the extrudate, there should beno sharp bends in the line. Roll and take up spooldiameters should be no less than 200 times thediameter of the extruded rod.

7.2.3 Pipe and tubing

A wide range of pipe and tubing diameters andthickness’ can be extruded using Vectra LCP. A meltpump between the extruder and the die provides asmoother, uniform extrudate and minimizes surging.It is recommended that extrusion melt temperaturesbe as low as possible to improve melt strength andincrease production rates.

Small diameter tubes (up to about 2 mm) can beextruded directly into a cooling trough, while sizing isrequired for larger diameters. Where uniform controlof diameter and roundness are critical, a vacuumwater-sizing bath is preferred. If a spider die design isused, the legs should be as far from the die outlet aspossible to allow a molten extrudate to rejoin andform a homogenous melt. The spider should becarefully centered to maintain a uniform wall thick-ness. A die land length of two or more times the tubediameter is ideal.

Sizing rings may be used to control outside diameteruniformity and smooth the outside surface of the pipeor tube. Sizing rings should be about 0.25 mm greaterin diameter than the product. A protruding mandrel isrequired for effective sizing of the inside tubediameter.

A drawdown ratio (the ratio of the die flow annulusdivided by the cross sectional area of the extrudedtube) of 1.2 to 2.0 is recommended for tubing.

7.2.4 Overcoating

Vectra A950 is recommended for overcoating of wireand optical glass fiber to provide extra protection andstrengthening of the fiber. The coated products havevery low thermal conductivity, moisture and gaspermeability, water absorption and coefficient ofthermal expansion.

Use a crosshead die with a converging nozzle forextrusion. A convergence ratio (ratio of the flow areacross section before and after convergence) of 10 to 20is required to induce molecular orientation for goodmechanical properties. The die land length should beabout 6 mm or less to avoid excessive heat transfer tothe glass fiber buffer coating.

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7

The cooling water trough should be maintained between 25°C to 45°C to prevent too rapid cooling of the jacketed fiber. Keep a distance of 15 to 20 cmbetween the die face and the cooling water. Rolls need to be placed so that the jacketed fiber is never bentaround a radius less than 100 times the jacketed fiberdiameter.

The coated fiber can be further oriented by drawdownafter exiting the die, which helps to increase tensileproperties. The recommended drawdown ratio is defined as:

Drawdown ratio = (A2-B2)/(C2-D2)

A = outside diameter of the die nozzle flow annulusB = inside diameter of the die nozzle flow annulusC = diameter of the coated productD = diameter of the wire or fiber

7.3 Troubleshooting

As with the injection molding troubleshooting guide(Section 6.4), many processing problems are caused by easily corrected conditions such as inadequate resin drying, incorrect temperatures, etc. Try therecommended solutions given below in the order inwhich they are listed under each problem category.

General extrusion

7.3.1 Extrudate cross section varies with time

- Check line speed uniformity- Check for extruder surging; reduce feed zone

temperature to restore even flow- Excessive draw down; adjust die dimensions- Install melt pump to stabilize flow rate

7.3.2 Extrudate has excessive voids

- If gassing appears to be a problem, reduce melttemperature or use vacuum vented extruder

- If melt pressure is less than 0.7 MPa, increase screwRPM, adjust die size, or use finer filter in screenpack (for unfilled resins) to increase melt pressure

7.3.3 Poor surface appearance

- Dry resin more thoroughly- If gassing appears to be a problem, reduce melt

temperature or use vacuum vented extruder- If striations occur, raise melt temperature in 2 to

3°C increments

7.3.4 Striations on extrudate in machine direction

- Check die for nicks- Check all equipment surfaces for contamination or

degraded resin

Pipe and tubing

7.3.5 Bowing of pipe or tubing

- Uneven cooling; make sure extrudate is completelysubmerged in cooling water

- Check for wall thickness variation- Check alignment of extrusion and sizing dies

7.3.6 Poor surface only on inner wall

- Check for material buildup on die mandrel- Adjust length of mandrel

7.3.7 Wall thickness variation

- Center the die mandrel

Profiles

7.3.8 Extrudate has distorted cross section

- Adjust melt temperature either higher or lower- Adjust die to water bath distance- Adjust drawdown ratio- Sizing may be required

7.3.9 Strand breaks in extrudate

- Dry resin more thoroughly- Raise melt temperature incrementally- Reduce drawdown ratio if there is a periodic

variation in cross section

Film and sheet

7.3.10 Large, uniformly spaced perforations in film

- Reduce melt temperature- Decrease die gap to reduce drawdown- Reduce die temperature

7.3.11 Sagging extrudate

- Lower melt temperature

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7.3.12 Uneven or distorted edges

- Polymer freezes up on die edges; clean die and raisemelt temperature

Overcoating

7.3.13 Breaks in optical fiber

- Make sure polymer and optical fiber are thoroughlydried

- Check for contamination in fiber guide- Adjust tension at the unwind stand and die entrance

7.3.14 Out of round cross section

- Reduce melt temperature- Center die tip nozzle- Adjust die to water bath distance- Adjust water bath temperature

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7

8. Rheology

Vectra® LCP has a nematic liquid crystal structure.The melt viscosity decreases continually with increas-ing deformation (shear) rate. At the deformation ratesthat normally occur during injection molding, themelt viscosity is lower than that of conventional filledor reinforced polymers (Figure 8.1).

Comparisons of melt viscosity as a function oftemperature for the important glass filled grades aregiven in Figure 8.2.

Melt viscosity of select Vectra LCP unfilled polymergrades commonly used in extrusion applications areshown in Figure 8.3. Vectra LKX1107 is a very lowmelt point LCP suitable for melt blending with othersemi-crystalline or amorphous resins to reduceviscosity.

With Vectra LCP, it is possible to fill very thin wallsdown to less than 0.2 mm. The injection pressures arelower than with amorphous or semi crystalline resins.Vectra LCP can be used to produce thin walledminiature parts and complicated parts with long flowpaths such as long, narrow connectors or small coilbobbins.

Despite good melt flow at the high shear rates, whichnormally occur in injection molding, Vectra LCP doesnot form any flash. It is possible therefore to moldthin walled articles and parts with movable coreswithout any flash. In the case of connectors and relays, for example, this can sometimes bring aconsiderable reduction in manufacturing cost because the costly deflashing step is unnecessary.

Vis

cosi

ty (P

a.se

c)

1000

Shear Rate (s-1)100 10000

10

100

1 10 1000

Liquid Crystal Polymer

ConventionalPolymer

Fig. 8.1 · Melt viscosity comparisonVectra LCP versus semi crystalline polymer

Vis

cosi

ty (P

a.se

c)

300


50

200

300 3202800

100

150

250

A130

L130 E130i

H130

Molding Range

Fig. 8.2 · Melt viscosity versus temperature(Glass filled grades at shear rate = 1,000/sec.)

Vis

cosi

ty (P

a.se

c)

600


100

400

300 3202200

200

300

500

A950

240 260 280

E950i

LKX1107

LKX1112

B950

L950

Fig. 8.3 · Melt viscosity versus temperature(Unfilled grades at shear rate = 1,000/sec.)

8

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9. Design

In most cases, designers and molders specify Vectra®

materials for their excellent dimensional stability,good flow in thin walls and mechanical toughnesswith a broad processing window. Part design is thekey consideration in optimizing both processinglatitude and part performance. In general, all of thestandard recommendations for good design of plasticparts are applicable when designing with Vectra LCP.For instance, parts should be designed and moldsconstructed to provide smooth, uniform flow of thepolymer melt. In addition, the part design mustcontrol the resins anisotropic properties – a fact thatpresents both opportunities and challenges. Thedirection of material flow in the mold influencesmechanical properties of the molded parts. Thus, thereis a strong link between part design, performance andend use requirements.

9.1 Part design

9.1.1 Nominal wall thickness

Of all the issues in plastic design, selecting the propernominal wall thickness is probably the most important.Choosing the proper wall sections sometimesdetermines the ultimate success or failure of a product.While an inadequate wall section can lead to poorperformance or structural failure, a section that is tooheavy, even in just certain regions, can make theproduct unattractive, overweight or too expensive.Although some problems can be corrected after themold is built, such solutions are often expensive.

The vast majority of injection-molded plastic partshave wall thicknesses in the range of 1 mm to 5 mm.Because of the low viscosity and easy flow of VectraLCP, typical wall thicknesses are in the range of 0.3 mm to 2 mm. Thickness within this range is generally related to the part size. This does not meanthat parts cannot be molded thinner or thicker, or that a big part can not be thin or a tiny part thick. However, these norms should act as a starting pointfor the design.If a part is subjected to any significant loading, theload-bearing areas should be analyzed for stress anddeflection. If the stress or deflection is too high, thefollowing alternatives should be considered:

a) use ribs or contours to increase section modulus;b) use a higher strength, higher modulus material;c) increase the thickness of the wall section if it is

not already too thick.

Plastic parts are good insulators for electrical and heatenergy. They can also serve as filters to sound,vibrations and light. In general, insulating ability isdirectly related to the thickness of the plastic. In thecase of sound transmission, a change in thickness maybe needed to change the resonant frequency of aplastic housing.

The impact resistance of a particular part is directlyrelated to its ability to absorb mechanical energywithout fracture or plastic deformation. This in turndepends on the properties of the resin and the geo-metry of the part. Increasing wall thickness generallyimproves the impact resistance of the molded part.However, increased wall thickness could also hurtimpact resistance by making the part overly stiff,unable to deflect and distribute the impact. Both ofthese methods of absorbing impact should be examin-ed when the nominal wall thickness is being selected.

9.1.2 Flow length and wall thickness

Melt flow lengths are determined in a spiral flow test,which closely simulates actual molding conditions.The spiral flow lengths of select grades at twodifferent thicknesses’ are shown in Figure 9.1.1. Thisinformation will give a relative measure of how far theplastic can be expected to flow from the gate. Thedesign engineer should also refer to the data presentedin Chapter 8 on rheology.

Leng

th (m

m)

800

100

B130 B230 H140 A130 A530 L130 E130i0

200

300

400

500

600

7002 mm Thickness

0.8 mm Thickness

Fig. 9.1.1 · Spiral flow lengths(Injection pressure: 195 bar hydraulic/2,000 bar

specific, mold temperature: 100°C)

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9.1.3 Shrinkage

The change in volume of Vectra LCP on solidifyingfrom the melt is considerable less than that of otherengineering thermoplastics. Shrinkage of Vectra LCPdepends mainly on orientation induced by the meltflow in the mold due to part design, wall thicknessand gating. In the flow direction, shrinkage may bezero or negative. Shrinkage anisotropy is reduced bythe use of fillers. Thicker sections shrink more, es-pecially in the transverse direction. The effects of meltand mold temperature, injection pressure and injectionrate are modest relative to other engineering plastics.Table 9.1 shows the effects of bar thickness, gating andmold temperature on shrinkage for selected VectraLCP grades.

Because of the low shrinkage, polished molds arerecommended to avoid ejection problems. If necessary, asuitable draft should be provided to assist removal fromthe mold. The low shrinkage of Vectra LCP coupledwith its low coefficient of thermal expansion (section3.2.3) offers the advantage of very high manufacturingprecision and close tolerances. This makes it possible toachieve high reproducibility of the part dimensionswhich can be a crucial advantage for automatic assembleof components leading to a considerable reduction inmanufacturing costs.

9.1.4 Draft angle

Vectra LCP exhibits very low shrinkage and unusuallyhigh stiffness. Consequently, they typically eject easilyfrom most cores. Parts have been molded with well-polished cores with lengths up to 40 cm and withoutany draft. Even so, molding parts without a draftshould be considered only when there are no alternateoptions. A draft angle of 1/10 to 1/4 degree per side issuggested. Larger draft angles provide easier ejection.

The same factors that allow molding of Vectra LCPwith minimal draft may result in parts sticking in themold if there are slight undercuts or rough areas. Withsome grades of Vectra LCP, a near zero flow directionshrinkage can cause sticking in the cavity side of themold rather than the core. Occasionally a core mayneed to be roughened to pull the part from the cavity.

Table 9.1 · Shrinkage Measurements (%)(127 x 12.7mm flex bar similar to Figure 3.2.10a with thickness and gating described below)

a) Vectra A130 – 30% glass reinforced

Flow direction Cross direction Z-direction

Mold Temperature 60°C 120°C 60°C 120°C 60°C 120°C

Thickness (mm) / Gate Location

3.2 / end 0.05 -0.02 1.2 1.1 5 5

1.6 / end -0.01 -1.01 1.1 1.0 3 2

0.8 / side 1.5 -0.02 0.1 0.2 5 5

b) Vectra A530 – 30% mineral filled




3.2 / end 0.2 0.12 1.4 1.4 5 3

1.6 / end 0.05 -0.03 0.9 1.2 1.4 1.6

0.8 / side 0.09 0.11 0.1 0.2 -7 -5

c) Vectra B130 – 30% glass reinforced




3.2 / end -0.02 -0.09 0.7 0.8 4 4

1.6 / end -0.05 -0.15 0.6 0.7 3 2

0.8 / side -0.02 -0.07 0.1 0 -9 -9

63

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9.1.5 Warp

Smooth, uniform flow of the melt is crucial tocontrolling warp. Wall sections should be as uniformas possible since parts are subject to warping if there isa heavy wall on one side and a thin one opposite.There is very little warp when the parts are designedso that resin flows evenly from one end to the other ina continuous, longitudinal path without weld lines.

The difference between mold shrinkage in the flowand cross flow direction is roughly comparable to thatfor other 30% glass fiber reinforced semi-crystallineresins such as PBT. The differential shrinkage can beeliminated or greatly reduced by relocating the gateand by suitable design of the part. With complicatedmoldings, it is extremely difficult to predict shrinkageexactly since the flow behavior of the melt andsubsequent orientation is difficult to foresee.

9.1.6 Knit lines

Knit lines or weld lines are weak points in any mold-ing made from reinforced plastics. In liquid crystalpolymers, the rigid molecular chains and reinforcedfibers, if present, are oriented largely parallel to theflow front. The reinforcement is therefore interruptedin the region of the knit line. Hence, great attentionmust be given to the knit lines.

Butt welds in which the melt fronts meet and remainin a plane perpendicular to the flow direction are particularly critical (Fig. 9.1.2). The LCP moleculesare oriented parallel to the melt front so that thestrength of a test specimen can be reduced by up to90%. A knit line such as this frequently leads to avisible surface mark.

Moldings with knit lines formed after the melt hasflowed around an obstacle (core) retain 50 to 60% ofthe transverse strength without a knit line (Figure9.1.2). The melt stream is divided into two at theobstacle and when the two streams reunite, welding isimpaired by melt cooling. When two melt streamsmeet directly behind the core at an obtuse angle,similarly low strength results as with a butt knit line(Figure 9.1.2). With growing distance from theobstacle, the two melt streams meet at an increasinglyacute angle until a parallel flow front has formed.Strength increases correspondingly with increasingdistance from the obstacle.

A molding without knit lines has the highest designstrength. If knit lines are unavoidable, they should besited in regions of low stress through suitable locationof the gate. If possible, butt knit lines should beavoided. Long knit lines after an obstacle are prefer-able to short butt knit lines.

One means to improve the strength of knit lines is tocreate an overflow well or tab. The melt can then flowfrom the end of the knit line into the overflow. Theoverflow is then trimmed off the molded part.

9.1.7 Ribs, corners, radii

The provision of ribs on molding walls is one possiblemeans to improve design strength and at the sametime avoid material accumulation due to excessive wallthickness. However, ribs influence melt flow in themold and can cause undesirable knit lines. If the flowdirection of the melt coincides with the longitudinalaxis of the ribs, the thickness of the ribs should be asnear as possible to the thickness of the adjacent wall(75 to 100%). The melt then flows in the samedirection through the rib and wall. If the rib is thinner there is a tendency for the melt to firstrush through the wall and then flow in the transversedirection into the rib. This would set up differentdirections of orientation and lead to warp. Any bossesshould be sized the same as the ribs.

butt weld line

Weld line afterthe melt hasflowed roundan obstacle,and strengthcurve(qualitative)

stre

ngth

2

1

Fig. 9.1.2 · Knit lines

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9

Rib connections to adjacent walls should be radiused.Radii of 0.1 to 0.2 times the thickness of the adjacentwall are recommended to reduce notch effects. Largerradii cause the melt to rush into the rib connectionpossibly resulting in undesirable knit lines or “backfilling” of the molded part.

Transitions, corners and molding edges should havegenerous radii provided this does not result in dis-advantages for mold filling (rushing of the melt, knitlines). For outside radii, 1.5 times the wall thickness isrecommended; for inside radii 0.5 times wall thickness.

9.1.8 Holes and depressions

Holes and depressions or thinner areas are particularlycritical design issues because of the need to carefullyconsider the impact of knit or weld lines on theintegrity of the molded Vectra LCP part. Typically, tomaximize the strength of a molded-in hole theminimum distance between the edge of the hole andthe edge of the part should be at least twice the holediameter or twice the nominal part wall thickness. Useyour judgement when choosing which guideline toapply, since the greater the distance the stronger thepart. This is especially critical when a fastener or apress-fit pin is inserted into the hole; the stress at thehole may cause a weak knit or weld line to fail. Similarrules hold for depressions, since they also generallycause a downstream knit or weld line. The designsituation is less critical, since there is generally noexternal stress imposed on a depression. If the partdesign is constrained to smaller than recommendeddimensions between the hole and edge of the part, theknit line may be strengthened by placing an“overflow” gate and well in the vicinity of the knitline. This can dramatically strengthen a weak knit line.

9.1.9 Latches, snapfits, interference fits

Latches designed using Vectra LCP should be tapered(typically a 2:1 taper) to provide a more uniform stressdistribution along the length of the beam. This designtechnique will limit the stress concentration at thebase of the latch. Additional deflection can also beachieved using this tapered beam approach.

Press fits depend on the interference of thecomponents to hold the assembly together. With lowelongation, high modulus materials such as VectraLCP, if the strain is too high, the material willfracture, losing the retention force designed to holdthe components together. Except for very light pressfits, this type of assembly can be very risky due to the

hoop stress in the boss, which might already beweakened by a knit line. Designing an interferencepress fit by adding “crush ribs” to the inside diameterof the boss or hole is a technique that can lower thestress while maintaining retention. Other techniquessuch as the use of barbs or splines on metal pins thatare inserted into the plastic can create interference andprovide effective holding forces.

9.2 Mold design

The quality of a molded part is essentially determinedby the following factors:- Properties of the molding material- Design of the molded part- Processing of the material

Only by optimizing all these factors can a high quality molded part be produced. For this reason,close cooperation between the material supplier, thedesigner and the end user is crucial.

Processing includes the machine, mold and temperaturecontrol units. Modern computing methods should beused in critical cases or complex moldings for themechanical, thermal and rheological design of a mold tosupport the experience of the designer.

It is often possible to assess whether a molded partwill meet requirements by applying the principles ofmaterials science but trials under actual or simulatedconditions should be carried out to confirm suitabilityfor the application.

9.2.1 Mold material

The selection of steels for the mold can be critical toits successful performance. Just as resins areformulated to satisfy processing and performancerequirements, steels are alloyed to meet the specificneeds for mold fabrication, processing and itsintended use. There are many different parts to themold, e.g. cavity, gates, vents, pins, cores, slides, etc.,and these may have different requirements. Forexample, some applications may require a mold steelwith high hardness to resist wear and abrasion at theparting line while another application may requiretoughness to resist mechanical fatigue. Usually, steelswith higher hardness and wear resistance propertiestend to be more brittle and steels with highertoughness will show less wear resistance. The selectionprocess of the tool steels should include input fromthe tool steel supplier, the mold designer and mold

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fabricator in addition to the resin supplier. Post-treatment of the mold can be used to reduce thepropensity for wear. Inserts should be consideredwhere wear may be a concern and long productionruns are anticipated. Table 9.2 lists some steels thatcould be considered for constructing a mold.

To achieve satisfactory protection against wear, therecommended hardness should be at least Rc ≥ 56,especially for processing highly filled grades.Recommended steels for Vectra LCP are through-

hardening steels like 1.2379 and maraging steel likeElmax® 1. As Vectra LCP is not corrosive, specialcorrosion-resistant steels are generally not required. Ifthe melt is injected against a wall or core, this area willbe subject to higher abrasion. In such areas, wearresistant materials, such as hard metal alloys likeFerro-Titanit® 2 S, should be considered or suitablesurface treatment carried out. The mold surfaceshould be smooth and polished to improve surfaceproperties and facilitate ejection. The molds can beheated with oil or water.

Table 9.2 · Partial Listing of Potential Mold Steels

Steel Type Hardness Properties Typical Applications DrawbacksUSA Ger.

D-2 1.2379 57-59 Good hardness, good abrasion resistance Gate inserts and cavity areas of Brittle and somewhat difficult to high wear from glass and fillers grind and assemble

A-8 56-58 Good adhesive wear resistance, Slides, lifters and cams Fair abrasion resistancegood toughness

A-6 56-58 Good heat treatment stability, General purpose, Moderate ductilityhigh hardness and compressive strength air hardened steel

A-2 1.2363 55-57 Air hardened steel, high abrasion Moderate ductilityresistance and good toughness

S-7 55-57 Very good mechanical fatigue resistance Fair adhesive and abrasive and toughness. wear resistance

O-1 1.2510 56-58 General purpose oil hardening steel Small inserts and cores. Medium to low toughnesswith moderate adhesive wear resistance

L-6 55-57 Very good toughness, oil hardening Medium hardness with medium with good heat treatment stability to low wear resistance

P-5 55-57 Highly malleable. Hobbing steel Case hardened. Low core hardness, low durability and heat treatment stability

P-6 55-57 Easily machined and welded Low heat treatment stability with medium to low durability

P-20 1.2311 28-34 Pre-hardened steel very tough, Large cavities Subject to galling and high wear easy to machine. Low hardness.

H-13 1.2344 50-52 Air or vacuum hardened steel Low hardnesswith very high toughness.

SS 420 1.2083 48-51 Very good chemical resistance. Low hardness, low mechanical fatigue strength, low thermal conductivity

Specialty Steels

M-2 62-64 Extreme hardness, abrasive and adhesive Gate inserts, core pins, Difficult and costly to machine wear resistance shut-off and part lines and grind

Böhler “M 340” 56 Corrosion resistant

Böhler “K 190” 60-63 Corrosion resistant

Böhler “M 390” 56-62 Corrosion resistant and highly dimensional stable

Zapp CPM T420V 57 Corrosion resistant, highly dimensional stable and easily polishable

Zapp CPM 3V 53-63 Corrosion resistant, highly dimensional stable and high toughness

Zapp CPM 9V 55-67 Highly dimensional stable Low corrosion resistance

WST “G25” 64-66 Corrosion resistant

Elmax 56-58 Highly wear and corrosion resistant

Ferro-Titanit S 66-70 Extremely high wear resistant and corrosion resistant

1 Trademark is registered by Bohler-Uddeholm Corp.2 Trademark is registered by Thyssen Stahl Aktiengesellschaft

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9

9.2.2 Finish

Mold finish plays an important role in determiningthe ease of processing as well as molded part appear-ance. Vectra LCP exhibits such low shrinkage thateven modest undercuts can cause poor ejection. EvenEDM (Electrical Discharge Machine) or erodingmarks can hold the part or imbalance the ejectionstroke. Therefore, the mold should be polished to SPI#2 (U.S.) finish or better. Deep or poorly drafted pins,cores and cavities require special attention. Finalpolishing should occur in the axis of ejection (drawpolishing).

9.2.3 Runner systems

All typical types of runner systems (hot runner,conventional cold runner or hot-runner with cold sub-runner) can be used for injection molding of VectraLCP. Both full round and trapezoidal runners areacceptable, but round ones are preferred. For multi-cavity tools, the runner system must be balancedcarefully to avoid filling and ejection problems.

When designing runner systems for Vectra LCP, thehigh impact shear on melt viscosity has to be takeninto consideration. To enable easiest filling more shearhas to be applied to Vectra LCP versus otherengineering plastics. Therefore, runners have to begenerally smaller in diameter and should continuouslyincrease shear. All extreme flow variations (diameter)are disadvantageous for consistent shear, viscosity andorientation. Due to the liquid crystal structure ofVectra LCP, melt and processing history have a greatinfluence on flow behavior and orientation. Aprincipal runner design for a typical Vectra LCP partcan be seen in Figure 9.2.1.

9.2.4 Gate location

Selecting the gate location requires consideration ofpolymer orientation, warpage, jetting and knit lineeffects. The gate location should control the cavityflow pattern to provide optimum properties in theaxis of maximum stress. In many cases, gating fromthe part-end is recommended.

As with mechanical properties, part shrinkage in theflow direction is smaller than that transverse. Theresultant shrinkage differential might cause warp.When flatness is critical, locate the gate to minimizeorientation (shrinkage) differences, i.e. balance themacross the part or relocate them to non-critical areas.Due to the high flow of Vectra LCP, single gates are

generally sufficient. Avoiding multiple gatesminimizes knit lines. When multiple gates areunavoidable, locate the gate so that knit lines occur inareas with lower mechanical loads and minimal strain.Note that seam-type knit lines are significantlystronger than butt-type knit lines. The gate should belocated so that the knit line is made earlier duringfilling of the part. Continued polymer flow willimprove the knit line strength.

As with all plastics, locate the gate to provide smoothand uniform filling of the part, usually from thick tothin sections. Gating directly into the thickest sectioncan cause problems. Jetting, for example, is a form ofnon-uniform polymer flow due to gating directly intoan open cavity section. To minimize jetting, the gateshould be located so that the melt stream impingesimmediately on a rib, core or nearby wall.

Since these effects must be carefully balanced, it isimportant to check the filling pattern when proofingnew or existing tools. Simply limit the shot size andinspect a series of short shots taken throughout cavityfilling, that is from the moment the melt comesthrough the gate to the point of final fill. In newtools, the gate area should be part of an insert tofacilitate changes or adjustments.

15-2

0 m

m

15 m

m

35-4

0 m

m

15-20 mm

Ø 1.8-2.0 mm

Ø 1.6-1.7 mm

Ø 1.6-1.7 mm

Ø 0.9-1.0 mm

Ø 0.3-0.8 mm

Fig. 9.2.1 · Typical Runner Design for Vectra LCP

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9.2.5 Gate size

Jetting is a phenomenon that results when plasticflows through a gate and into a cavity withoutsticking to the mold walls. It produces a rope-likeflow or “jet” which is then compressed in the part.Ideally, the polymer should form a uniform flow frontthat fills the cavity smoothly. Vectra LCP has verylittle die swell when exiting the gate and thus is moreprone to jetting than many thermoplastics.

Techniques for controlling jetting are similar for allplastics. Edge gates should be large, generally 100% ofwall thickness. For three plate molds, tunnel gates andsome edge gates, a smaller gate is practical andsometimes necessary for a clean break, provided thatthe flow is directed against a core or cavity wall tocontrol jetting and force a uniform flow to develop.Vectra LCP is stronger in the flow direction, thereforetunnel gates should be located in the ejector side ofthe mold to push rather than pull the gate and runnersfrom the mold. On three plate molds, gate diametersshould be between 20% and 50% of the wallthickness to ensure that the gate breaks easily.

9.2.6 Gate design

As with gate location, it is important to select the gatetype appropriate to the part geometry. To minimizeknit lines and differential shrinkage the gate shouldprovide a uniform flow front. Molders usually usesubmarine gates for Vectra LCP. Other gate types areused occasionally.

9.2.6.1 Submarine (tunnel) gates

Submarine gates (Figure 9.2.2) require careful sizing tobalance ejection difficulties of large gates with jetting and filling limitations of small gates.Furthermore, the drop from the runner must flexenough to clear the cutting edge as the tool opens.Vectra LCP is very stiff so the gate design mustmaximize flexibility and minimize the deflectionrequired during ejection. The runner should be smalland close to the part l1. The converging angle of thecone should be relatively small (about 30°) and thedrop angle from the runner relatively steep (about60°). Most importantly, the submarine gate shouldextend into the ejector side of the tool so the ejectionstroke can positively separate the runner from thepart. The ejectors should be robust and close to thegate because Vectra LCP has very high tensile andshear strength in the highly oriented gate drop. If the

submarine gate extends into the stationary side, therunner could split at the pullers rather than break atthe gate.

9.2.6.2 Pin gates

Pin gates are used for thin sections and easy degatingin most 3-plate tools. As with any small gate, directthe polymer flow onto a core, rib or cavity wall tocontrol jetting. If this approach is impractical, enlargethe gate to minimize jetting. Note that gate diametersgreater than 1.5 mm require caution because largegates can be difficult to break as the mold opens.

9.2.6.3 Edge gates

The rectangular edge gate is a general-purpose gatewith several variations. The most basic form has noobjects to deflect polymer flow and gate height at 90to 100% of the wall thickness. The gate land shouldbe slightly offset from the part surface to minimize“skinning” during gate removal. Use obstructions onthe core or cavity wall to avoid jetting.

9.2.6.4 Film gates

Film gates are recommended for flat, rectangularparts. A sufficiently thick transverse runner in frontof the film ensures that the melt is distributed evenlyacross the land before entering the cavity. This way ahomogeneous filling process is guaranteed, orienta-tions are in line and warpage minimized.

d1 = 2 - 0.8 mmd2 = 0.3 - 0.8 mml1 = minimala = 30 - 35°b = 30°R = >2 mmNo sharp corners

d1

l1

d2

Gating

R

a

b

Fig. 9.2.2 · Submarine gate

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9

9.2.6.5 Ring and diaphragm gates

For cylindrical parts, a uniform flow front is critical tomaintain concentricity, dimensional stability, partperformance and appearance. A diaphragm or ringgate provides the best gate designs to obtain theuniform flow front. In both types, the gate land ormembrane should be significantly thinner in crosssection (shallower) than the runner ring or centraldisk. This thickness differential forces the ring or diskto fill completely before the melt fills the membrane.Furthermore, the long thin land of the gate orients thematerial before entering the part.

The choice of ring or diaphragm depends on part andtooling features. With an internal ring or diaphragmgate, the gate vestige is internal to the part but,depending on the tool layout, the core may not seat assolidly as with an external ring. With an external ringgate, the core can be solidly seated but the gate vestigeis external. The dual feed to the ring gate minimizesboth time and pressure needed to fill the ring.

9.2.6.6 Overflow gates

A very effective technique for strengthening the knitor weld lines in Vectra LCP parts is to cut an overflowgate and well into the tool. Changing its internalsurface contour from a flat plane to a sort of tongueand groove configuration strengthens the normallyrelatively weak “butt” knit or weld line. This is doneby normally forming the part during the filling stageof the molding process. Then during the packing stepcausing a small amount of flow at the knit plane as theoverflow gate is activated by the high pressure. Tocreate a successful overflow design, the mold must becompleted, the part dimensions correct and the moldready for final polishing, i.e., NO further changes inthe metal contours.

The key to a successful design is to put the overflowgate just slightly off the knit line. Parts must be mold-ed under appropriate conditions to get a robustprocess; knit lines are located on the part and theoverflow gate can then be located about 11/2 to 21/2

nominal wall thicknesses away from the knit linelocation. A submarine or tab gate can be used; how-ever, it must have a small enough area that flowONLY occurs after the part starts to pack out. Thiswill ensure a complete filling of the mold and properformation of the weak knit line before the plane of theknit line is altered by the overflow. If the location istoo near or too far from the knit, there will be no flowthrough the knit and no strengthening of the knit line.

A removable insert at the approximate location of theknit line can facilitate experimenting with theoverflow location to improve knit line strength.

9.2.7 Vents

The melt viscosity of Vectra LCP decreases markedlywith increased injection rate. Furthermore, fastinjection rates can improve knit line strength. In manycases, the molder may need to increase injectionvelocity so that the tool should be well vented. SinceVectra LCP has extremely low melt viscosity the ventsshould be no deeper than 0.01 to 0.025 mm. Ventsshould be located in sections of the cavity where aircould be trapped during filling especially at knit lines.Vents at several locations in the tool avoid forcing allof the air through one opening.

9.2.8 Ejection

The ejection of a molded part is generally by ejectorpins or ejector blades. These are round or rectangularshaped pins used by the available areas for productremoval. The main purpose of the blade ejector is forthe ejection of very slender parts, such as ribs andother projections, which cannot satisfactorily be eject-ed by standard type of ejector pins. The location andnumber of the ejector pin/blade elements aredependent on the component’s size and shape. Theaim of the designer must always be to eject the mold-ed part with as little distortion as possible. Whateverejector system is chosen, ejection must never causedamage to, or permanent deformation of, the moldedpart. The mold preferably should be fitted withejectors at weld lines and at those spots around whichthe molding is expected to shrink (i.e., around cornersor male plugs).

The ejector pins should be located so that the moldedpart is pushed off evenly from the core. Once the sizeof the ejector pins is decided, then the greater thenumber of ejector pins incorporated the greater willbe the effective ejection force and the less the likeli-hood of distortion occurring. For this reason it is better to err by having too many ejector pins than byhaving too few. The molder and mold-maker usuallyare able to predict knockout problems. Often aestheticconsiderations or lack of room for knockouts preventusing the number and size of pins desired. It is poorpractice to build a mold under these conditions. Ifsatisfactory ejection cannot be designed initially onpaper, it will be difficult, if not impossible, to install iton the completed mold. Sometimes the parts have to

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be redesigned or made in two pieces and joined later.Unless a molded part can be ejected consistently, aneven cycle cannot be maintained, and the part cannotbe produced on a commercial basis.

9.2.8.1 Sprue puller

Experience has shown that “Z-claws” or “Z-puller” is preferred for Vectra LCP because of the uniquematerial characteristics. Figure 9.2.3 gives a designrecommendation for sprue puller suitable for Vectra LCP.

5°

R = 0.5

Fig. 9.2.3 ·Sprue Puller 10. AnnealingThe high heat deflection resistance of Vectra® LCP can be further raised 30 to 50°C by thermal after-treatment of the molded parts. Annealing can also beused to improve the flatness of a part by fixturing thepart while carrying out the thermal after-treatment.This process can be carried out in air or nitrogen in acirculating air oven under the following conditions:

Vectra A-series and Vectra B-series- Heat oven from room temperature to 220°C over

2 hours- Gradually increase temperature from 220 to 240°C

over 1 hour- Maintain at 240°C for 2 hours- Gradually increase temperature from 240 to 250°C

over 1 hour- Maintain at 250°C for 2 hours- Cool to room temperature

Vectra C-series and Vectra L-series- Heat oven from room temperature to 220°C over




Vectra Ei-series and Vectra H-series- Heat oven from room temperature to 220°C over




During annealing, the natural beige color of VectraLCP changes to a pale brown.

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9

11. Finishing and Assembly

The finishing and assembly of Vectra® LCP parts isquite similar to that of conventional semi-crystallineplastics like nylon and polyesters. A factor that mustbe considered in the design of joints and fasteningtechniques is the relatively weak weld or knit linestrength of liquid crystal polymer materials. Any jointformed by melting parts to fuse them together musthave some shearing deformation over a large enougharea to form a strong joint. When using any fastenerthat causes a high stress on the knit or weld line eitherduring assembly or service, the strength of the knit orweld lines must be considered. Although Vectra LCPsare very chemically resistant, they can be successfullyjoined with adhesives, both with and without surfacetreatment. As with all injection-molded parts, VectraLCP machined prototypes are poor imitations of theactual part because most of the advantages anddeficiencies of Vectra LCP are developed during flowduring the injection mold.

11.1 Welding

With the current trend towards rationalization andeconomic production of plastic assemblies, joiningtechnology is becoming increasingly important. Forproduction and assembly reasons, it is often anadvantage to join molded parts after manufacture.

11.1.1 Ultrasonic welding

The most important aspect of welding Vectra LCP isthat a shear joint be used. During ultrasonic weldingwith Vectra LCP, the joint strength depends mostlyon the shear length; the longer the shear length yieldshigher strength. Other types of joint designs, such asenergy director, scarf and butt joint result in lowstrengths. The shear joint should be designed in a conventional manner for a high modulus material,that is with about a 0.1 to 0.6 mm interference and a0.5 to 2.6 mm depth (Figure 11.1.1). The strength ofthe weld joint will be determined more by the depthof the joint than by the interference. The interferenceshould be proportional to the wall thickness.

All high melting point plastics require high-energyinputs to weld and Vectra LCP is no exception. Formost welding applications, a 20 kHz machine shouldbe adequate. For very small parts, less than 13 to 19 mm diameters, a 40 kHz machine should be con-

sidered. Horn amplitudes will be large, generally be-tween 0.05 and 0.08 mm for a 20 kHz frequency andabout half that for a 40 kHz frequency machine.

The expected weld strength will depend on both theactual welding conditions and the grade of VectraLCP being used. Joint shear strength of about 30% to50% of the bulk material strength should be expectedwhen the above guidelines are followed. Figure 11.1.2shows the relative strengths of the joint for variousVectra LCP grades using the American WeldingSociety Test Specimen.

> 2

˜ 0.1

0.1

0.2 - 0.4

30°

Fig. 11.1.1 · Ultrasonic welding joint design

Shea

r St

reng

th (l

b f)

700

100

A150 A130 B230 B130 L130 A435 E130i0

200

300

400

500

600

Part DesignStep w/interferenceper side: 20 mil(0.5 mm)

Time (seconds)Weld: 1.0 secHold: 1.0 sec

Pressure (PSI/N)Weld: 60/267Hold: 30/133

3000N

ewto

ns

0

2500

2000

1500

1000

500

Vectra LCP grades

Fig. 11.1.2 · Ultrasonic weld strengths

10

11

Vectra®


During ultrasonic welding tests, sonotrode wear wasobserved which could be avoided by using a hardmetal material or a polyethylene layer as a buffer. Due to the stiffness of Vectra LCP, the ultrasonicwelding process can be noisy. A silicon rubber layerunderneath the parts helps to diminish the noise.

11.1.2 Rotational (spin) welding

Joint design is critical for maximizing weld linestrength. With the optimum design (Figure 11.1.3),strength of 50% of the material properties can beachieved. Due to the compressive behavior, it isdifficult to evaluate the correct joint area in the part.Figure 11.1.4 gives representative values of weldstrengths for comparison.

11.1.3 Hot plate welding

Hot plate welding is not recommended for VectraLCP because of the very weak joints. The strength of the weld is between 12 – 15% of the materialstrength. There is no significant difference betweenthe flow and the transverse direction. The part shouldnot have direct contact with the hot plate due to thetendency of Vectra LCP to bond onto the plate.Radiant heat transfer alone supplies enough heatenergy for the process.

11.1.4 Vibration welding

With vibration welding, the specific polymer structureof Vectra LCP causes either long welding times withlow pressure or short welding times with high pressure (Figure 11.1.5). Low welding pressure isrecommended. With a low welding pressure, a highstrength of about 16% of the material properties can be achieved. It is not recommended to weld parallel to the flow direction.

100%

66%

5 m

m

2 m

m

Fig. 11.1.3 · Spin welding joint design

Processing Parameters: Speed = 0.84 m/secTrigger pressure = 1 barWeld pressure = 3 barWeld length = 1.29 mmRotation impulse x 360° = 2

0 1000 2000 3000Carrying capacity of the weld line (N)

C130

A530

A130

Fig. 11.1.4 · Spin weld strengths for Vectra LCP

With a forceover 4 MPathe elongationwill be betterbut thestrength willbe reduced.

Vectra C130is moreinsensitive tojoint pressurevariations.

Vectra A530has the beststrength anelongation at3 MPa.

Processing Parameters: Frequency = 240 HzAmplitude = 1.4 mmJoint pressure = <1 MPa(for Vectra A530 Joint pressure = 3 MPa)

Vectra A130

Vectra C130

Vectra A530

Stre

ngth

PressureEl

onga

tion

Stre

ngth

Pressure

Elon

gatio

n

Stre

ngth

Pressure

Elon

gatio

n

Fig. 11.1.5 · Vibration welding

72

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11

11.2 Adhesive bonding

Parts made from Vectra LCP can be effectively bond-ed using readily available commercial adhesives. Inmost cases, the bond strengths obtained with un-modified surfaces are more than adequate for productassembly. Adhesive bond strengths can be furtherenhanced by surface treatments which improve wetting, such as plasma treatment, corona treatment,light sanding, grit blasting or chromic sulfuric acid(Chromerge®) etching.

Most importantly, when bonding any molded plasticpart, optimum adhesion will be obtained only whenthe parts are clean, the adhesive is fresh and theprocedure supplied by the adhesive manufacturer isfollowed precisely. It is nearly impossible tocompletely clean mold release from a molded partand mold release will prevent good adhesion. So, donot use mold release. Surfaces to be bonded shouldnot be touched after cleaning because an oil film maybe deposited which could interfere with adhesion.

Certain grades of Vectra LCP provide greater bondstrength than others. Generally, filled or reinforcedgrades of Vectra LCP provide greater bond strengthsthan unfilled grades. Table 11.2.1 a, b and c showtypical lap shear strengths (ASTM D 3163) obtainedwith a variety of adhesives tested at 22°C, 100°C and150°C, respectively. Before specifying these or anyother adhesives, the end user should make certainthat all mechanical, thermal, electrical, chemical andother properties of the adhesive are suitable for theapplication in question. Please note these data are ageneral screening of classes of adhesives, not aspecific recommendation. Table 11.2.2 presentscommercial examples of the adhesives represented inTables 11.2.1 a, b and c. Table 11.2.3 includesexamples of adhesives that comply with either FDAregulations or United States Pharmacopoeia (USP)Class VI requirements. A list of supplier informationis also included.

pressure

electro bobbincan

metal ring

lid

Processing Parameters:

Testing model: can and lid with diameter = 30 mmand thickness = 3 mm

Cross section of ring: 2.25 mm_ (Steel C45)Welding equipment: KVT, Type 010, generator UTG 20/3000Welding time: 45 secHolding time: 20 secPower of generator: 2700 Watt (scale 90%)

Fig. 11.1.6 · Electromagnetic welding

11.1.5 Hot and cold staking

Hot staking is the preferred way to form a “head” ona Vectra LCP boss or rivet. Typically, a very hardsurface is recommended for the heated forming tool toreduce wear when heading bosses in parts moldedfrom the most often used Vectra LCP glass reinforcedresins. Heating rates and temperatures are similar tothose used with other semi-crystalline or amorphousthermoplastics like polyesters, nylons andpolycarbonates. Dwell times, temperatures relative tothe nominal melting points or softening temperatures,pressures and cycle times should be establishedexperimentally on molded prototype parts to makesure the parameters for a robust production processare known before investing in capital equipment.

Cold staking is not recommended for Vectra LCP,since the resin is too hard and brittle to form withoutbeing heated and softened or melted.

11.1.6 Electromagnetic welding

Electromagnetic welding is suitable for Vectra LCP.The welding quality depends on process parameters,which have to be defined together with the equipmentmanufacturer. For efficiency reasons, the longerwelding times can be compensated for by a multiplewelding system. During welding trials (Figure 11.1.6)with Vectra A130 and Vectra A625 the partswithstood a break load of 1,300 to 1,650 Newton(Table 11.1.1). All bonds were hermetic seals.

Table 11.1.1 · Electromagnetic welding strengths

Variant Pressure (bar) Depth Gastight Load to break Trigger Welding (mm) 10 min./2.5 bar (N)

Vectra 0.5 1.0 3.2 – 3.4 Yes 1,664 ± 57A130 1.0 2.0 3.4 – 3.5 Yes 1,542 ± 162

1.0 3.0 3.4 – 3.5 Yes 1,550 ± 119

Vectra 0.5 1.0 2.3 – 2.6 Yes 1,302 ± 288A625 1.0 2.0 2.8 – 3.2 Yes 1,752 ± 445

1.0 3.0 3.2 – 3.3 Yes 1,665 ± 108

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Table 11.2.1 · Lap shear strength

a) Testing Performed at 22°C

Adhesive Type Range of Values, N/mm2 Average Values, N/mm2

As Molded Surface Treated* As Molded Surface Treated*

2 Part Epoxy 3.1 - 6.9 5.5 - 14.5 4.8 9.0

1 Part Epoxy 4.1 - 9.0 5.5 - 9.7 6.2 10.7

Cyanoacrylate 2.1 - 4.8 3.4 - 6.9 3.4 5.5

2 Part Acrylate 1.7 - 5.5 3.4 - 5.5 3.1 4.8

b) Testing Performed at 100°C



2 Part Epoxy 1.0 - 2.1 1.0 - 2.8 1.4 2.1

1 Part Epoxy 1.4 - 4.8 1.7 - 5.5 3.4 4.1

Cyanoacrylate 2.1 2.1 - 3.4 2.1 2.8

2 Part Acrylic 0.7 - 1.4 1.4 - 2.1 1.0 1.7

c) Testing Performed at 150°C



2 Part Epoxy 0.7 - 1.4 0.7 - 1.4 0.7 1.0

1 Part Epoxy 0.7 - 2.1 0.7 - 2.1 1.4 1.4

Cyanoacrylate 0.2 - 0.3 0.3 - 0.7 0.2 0.7

2 Part Acrylic 0.3 0.7 0.3 0.7

*Light sanding or grit blasting and solvent wash

Table 11.2.2 · Typical Adhesives for Vectra LCP

Supplier Grade Family Cure Temp Range(°C)

Lord Corporation Fusor® 310 2 Part Epoxy 15 minutes at 105°C -40 to 205

Ciba Specialty Chemical REN® DA-556 1) 2 Part Epoxy 5 minutes at 80°C -30 to 90

3M Adhesives Scotch-Weld® 1838 A/B 2 Part Epoxy 30 minutes at 95°C -55 to 175

Cole-Parmer Co. 5 Minute Epoxy 2 Part Epoxy 1 hour at 20°C -30 to 95

3M Adhesives Scotch-Weld® 2214 Hi-Temp 1 Part Epoxy 10 minutes at 150°C -55 to 175

3M Adhesives Scotch-Weld® 2214 Hi-Temp, 1 Part Epoxy 15 minutes at 150°C -55 to 230New Formula

Epoxy Technology, Inc. EPO-TEK® H35-175MP 1 Part Epoxy 1.5 hours at 175°C -50 to 160(Electrically Conductive)

Emerson & Cummins ME-868-2Specialty Polymers (Thermally Conductive) 1 Part Epoxy 1 hour at 165°C -75 to 170

Permabond International Permabond® 102 2) 1 Part Cyanoacrylate 30 seconds at 23°C -60 to 80

Permabond International 610/612 2) 2 Part Acrylic 25 seconds at 23°C -80 to 150

Fisher Scientific Chromerge® Etching Acid

1) REN is the registered trademark of REN Plastics Co.2) Permabond is the registered trademark of National Starch an Chemical Corp.

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11

Supplier Information

North America

Ciba Specialty Chemical4917 Dawn AvenueEast Lansing, MI 48823 USAPhone: 517-351-5900Fax: 517-351-6255

Cole-Parmer Co.7425 North Oak Park AvenueChicago, IL 60648 USAPhone: 847-549-7600Fax: 847-247-2983

Epoxy Technology, Inc.14 Fortune DriveBillerica, MA 01821 USAPhone: 800-227-2201Fax: 508-667-4446

Fisher Scientific50 Fadem RoadSpringfield, NJ 07081 USAPhone: 201-467-6400Fax: 201-379-7638

IPN151 Essex StreetHaverhill, MA 01832, USAPhone: 508-372-2016Fax: 508-374-6955

Emerson & Cummings Specialty Polymers55 Hayden AvenueLexington, MA 02173 USAPhone: 800-832-4929Fax: 617-861-9590

11.2.1 Surface preparation

Adhesion will be improved by proper surfacepreparation. Gas plasma technology has been used to improve the adhesive bond strength betweenVectra LCP and epoxy and urethane adhesives. Table 11.2.4 shows the effectiveness of plasmatreating to promote adhesion.

11.3 Fasteners

11.3.1 Screws

Vectra LCP can be used for producing parts that willbe joined together by screw coupling. Trials weredone to create the design and evaluate the ratio ofscrew/hole dimensions. The screw hole diametermust be designed with very narrow tolerances. Table 11.3.1 gives typical dimensions for a screw.

Europe

Ciba-Geigy GmbHOflinger Strasse 44D-79664 Wehr/Baden GermanyPhone: 49-7762-820Fax: 49-7762-3727

Nova Direct GmbH(A Cole-Parmer Distributor)Am Storchennest 24D-77694 Kehl/RheinGermanyPhone: 49-78-51-7069Fax: 49-78-51-75362

Poly Tec(An Epoxy Technology, Inc.Distributor)Poly Tec-Platz 1-7D-76337 WaldbronnGermanyPhone: 49-7243-6040Fax: 49-7243-69944

Fisher Scientific GmbHBinnerheide 33D-58239 SchwerteGermanyPhone: 49-2304-4780Fax: 49-2304-46052

Table 11.2.4 · Lap shear strengths

Vectra A130 Vectra A625Epoxy Urethane Epoxy Urethane

No treatment 7.2 MPa 0.9 MPa 6.5 MPa 1.3 MPa

Oxygen plasma 11.4 MPa 9.3 MPa 11.0 MPa 6.7 MPa

Ammonia plasma 8.8 MPa 10.5 MPa 8.6 MPa 7.2 MPa

Table 11.3.1 · Typical screw dimensions

Material Screw-type Hole Part Screwing (EJOT) Diameter db Diameter D Depth te

Vectra A130 PT 0.84 x d 1.90 x d 1.80 x d

Vectra E130i PT 0.86 x d 1.90 x d 1.80 x d

Vectra B230 PT 0.90 x d 2.00 x d 1.90 x d

Table 11.2.3 · Adhesives Compliant with US Regulations

Supplier Grade Family Cure Temp Range (°C ) In Compliance

Tra-Con Tra-Bond FDA-8 2 Part Epoxy 4 hours at 65°C -51 to 150 FDA*

Epoxy Technology Epo-Tek 301 2 Part Epoxy 1 hour at 65°C USP Class VI

Pacer Technology PX500 Cyanoacrylate 30 seconds at 20°C -55 to 95 USP Class VIPX5 Cyanoacrylate 30 seconds at 20°C -55 to 95 USP Class VI

Loctite Medical Adhesive 4013 Cyanoacrylate 30 seconds at 20°C -40 to 105 USP Class VI

* In compliance with FDA Title 21, US Code of Federal Regulations, Food and Drug Administration (FDA) Chapter 1, Sub Part B, Sections 175.105 and 175.300.

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Figure 11.3.1 shows an example of a boss designed foran Ejot PT® K screw. Design recommendations anddimensions are shown in Table 11.3.2.

11.3.2 Ultrasonic inserts

Brass inserts are used to provide metal threads inthermoplastics. The inserts are installed using ultra-sonic or heat equipment that develops heat betweenthe insert and the plastic. The heat remelts the narrowzone around the insert which, once resolidified pro-vides a high strength molded-in insert.

The Ultrasert II insert from Heli-coil has steppedinclined ribs that continually present new metalsurfaces to the plastic, thus forming a continuous zoneof melting and solidifying during installation.

This creates a homogenous structure around the in-sert. The Ultrasert II has a unique knurled flange,which provides positive downward compressive forceto the molten plastic that assures complete filling ofthe grooves for torque resistance. Table 11.3.3 givesthe performance of these inserts in Vectra LCP inthree essential areas.

Fig. 11.3.1 · Boss for Ejot PT® K Screw

de = nominal screw diameter (d) + 0.2 mm

de

2/3 S

db

S

0.3

- 0.5

d

te

Table 11.3.2 · Ejot PT® K Screw

EJOT PT® K thread nominal screw hole diameter, Penetration driving stripping pull out forming screw diameter, d db depth, te torque torque strength

(mm) (mm) (mm) (N-m) (N-m) (N)

Vectra A130 PT K 50 X 12 5 4.2 9.5 0.84 4.21 4170

PT K 30 X 10 3 2.5 9.5 0.43 1.36 1640

Vectra E130i PT K 50 X 12 5 4.4 9.5 0.54 2.38 2680

PT K 30 X 10 3 2.5 6 0.37 1.09 1340

PT K 50 X 12 5 2.6 6 1220

Vectra B230 PT K 50 X 12 5 4.4 9.5 0.79 2.6 3050

PT K 30 X 10 3 2.7 6 0.4 1.09

Table 11.3.3 · Performance of molded-in inserts(Dodge Ultrasert II inserts*)

Thread Size Part number Tensile Rotational Jack-outstrength torque

(lbs.) (in-lbs.) (in-lbs.)

#2-56 6035-02BR115 94.5 7.8 2.5

6035-02BR188 222.0 9.3 3.6

#4-40 6035-04BR135 189.3 24.8 9.0

6035-04BR219 396.5 25.3 15.3

#6-32 6035-06BR150 239.8 28.5 7.5

6035-06BR250 490.5 32.0 16.8

#8-32 6035-2BR185 305.5 33.5 17.8

6035-2BR312 505 50.8 26.0

#10-32 6041-3BR225 372.8 55.8 32.5

*Emhart Heli-Coil, Shelter Rock Lane, Danbury, CT 06810Phone 203-743-7651, Fax 203-798-2540

Ultrasonic insertion conditions (Branson Ultrasonic welder, model 8700):

Thread size Booster Weld time Hold time Air pressure(Seconds) (Seconds) (psi)

#2 Black 0.4 0.5 15

#4 Black 0.5 0.5 15

#6 Black 0.6 0.5 20

#8 Black 0.6 0.5 20

#10 Black 0.7 1.0 20

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11

11.4 Decoration

11.4.1 Printing

Printing on untreated, freshly molded Vectra parts hasbeen successfully demonstrated using one and twopart component inks. Pretreatment such as corona,flame impingement, or plasma surface treatment maynot be necessary. Ink suppliers are willing to assistwith the selection of appropriate inks to match yourspecific application. In most cases, they have theexperience to guide the customer through thecomplete process. If necessary, they can modify theinks and even test trial parts.

Markem Corporation150 Congress StreetKeene, New Hampshire 03431Phone (603) 352-1130

ColorconA Division of Berwind Pharmaceutical415 Moyer BoulevardWest Point, Pennsylvania 19486-0024Phone (215) 699-7733

Tampoprint USA1400, 26th StreetVero Beach, Florida 32960Phone (561) 778 8896

Tampoprint GmbHLingwiesenstrasse 170825 Korntal-MünchingenGermanyPhone ++49 (0) 7150-928-0

11.4.2 Painting

Vectra LCP resin has been successfully painted,however painting LCP resin can be difficult. Becausethe plastic substrate is chemically inert, Vectra LCPcan not be chemically etched to enhance adhesion.Pretreatment with a primer is recommended, as manyone-coat systems do not give sufficient peel strength.Pretreatment with Ditzler Polypropylene primer, code#DPX801 has been demonstrated successfully. Thesurface must be cleaned as per Ditzler standardprocedures. After the primer, enamel paints with highsolids give a good finish coat. Refer to Ditzler productdata sheet for topcoat recommendations.

Ditzler/PPG IndustriesOne PPG Place, 37 NorthPittsburgh, Pennsylvania 15272Phone: (412) 434-3131Customer service: 888-774-1010

Schramm Lacke GmbHKettelesstrasse 100D-63075 Offenbach/MainGermanyPhone: ++49 (0) 698603-0

Herberts Austria GmbHStock IndustrialackeModlinger Strasse 15A-2353 GuntramsdorfAustriaPhone: 0043-2236-53483

Berlac AGAllmendweg 39CH-4450 SissachSwitzerlandPhone: 0041-61-9713666

11.4.3 Laser marking

Non-contact permanent marking of texts, patterns andserial codes by laser beam is possible with Vectra LCPsurfaces. Two suitable laser-marking methods can beused:

- Laser scanning with a Nd:YAG laser- Mask projection technique with excimer or

CO2 laser

One suggested marking condition follows:

Energy – 18 amperesFrequency – 5,000 HzMinimum writing size – 1 to 2 mm

Nd/YAG lasers on natural Vectra LCP surfacesproduce anthracite-colored markings; on black VectraLCP surfaces, they produce pale gray markings.

Specialty formulated grades with pigment combina-tions providing a higher contrast are also available.

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11.5 Metallization and molded interconnect devices

The Metallization of Vectra-LCP

The combination of Vectra LCP’s properties makes itvery suitable for metallization. The Vectra 800 series,for example Vectra E820i, has particularly been devel-oped for this purpose, and has been modified withspecial types of mineral. These products allow micro-roughness to be generated on the surface of the partby an alkaline etching process, so that the metal layeris provided adequate facility for adhesion. Processing chemicals can be supplied by SHIPLEY,OMI-ENTHONE or ATOTECH.

The adhesive strength of the metal layer depends onthe injection molding parameters (drying, injectionspeed, cylinder temperature and mold temperature),the etching process and the test equipment. If theserecommendations are followed, adhesion strengthsfrom 0.9 to 1.5 N/mm can be reached. Themetallization process is shown schematically below.

The chemically deposited layer of copper is generally2 – 3 µm thick. The individual process parametersdepend on the applications that have been developedby the various firms. After the etching and thedeposition of copper over the whole surface, copperis then electrolytically applied until the desired layerthickness is achieved (approximately 20 – 30 µm). Abarrier layer of nickel is then applied, and the surfaceis finished with tin / lead or with gold. Vectra E820i,C810 and C820 are Vectra grades that can be con-

sidered for wet chemical metallization. Vectra E820iPd is used in a special process to manufacture 3D-MID components (see the section on MID).

In sputtering, the metal that is to be used to coat the component is subjected to ion bombardment torelease ionized atoms into a surrounding vacuum.The atoms drift along the potential gradient from the metal source to the plastic part, where theyaccumulate in a hard, even layer. The thickness ofthat layer depends on the sputtering time. In practice,thicknesses of up to 5 µm are achieved with Vectra LCP.

In aluminum vapor deposition, the components areplaced in an evacuated chamber, that also containsaluminum blocks as the source of metal. Very hightemperatures cause the aluminum to vaporize, andthe aluminum cloud precipitates on the components.This procedure is applied to Vectra LCP for screen-ing elements and reflectors, amongst other uses.

The addresses of some firms who have acquiredknowledge of Vectra LCP metallization are included here:

In Europe:

FUBA Printed Circuits GmbHBahnhofstraße 3D-37534 Gittelde / HarzGermanyTel.: ++49 (0) 5327-8 80-5 80Fax.: ++49 (0) 5327-8 80-2 00

Siegfried Schaal Metallveredlung GmbH & Co.Laucherthaler Straße 30D-72517 SigmaringendorfGermanyTel.: ++49 (0) 7571-72 09-0Fax.: ++49 (0) 7571-72 09-23

Lüberg Elektronik GmbH & Co. KGHans-Stiegel-Straße 3D-92637 WeidenGermanyTel.: ++49 (0) 961-2 70 18Fax.: ++49 (0) 961-6 21 09

Werner Flümann AGRingstraße 9CH-8600 DübendorfSwitzerlandTel.: ++41 01-8 21 31 70Fax.: ++41 01-8 21 31 04

Molding

Etching

Activating surface

Applying copper chemically

Applying copper electrolytically

Finishing the surface (gold, tin/lead)

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11

Philips Competence Centre Plastics B.V.Building SEH-6NL-5600 MD EindhovenNetherlandsTel.: ++31 (0) 4 02 73 37 22Fax.: ++31 (0) 4 02 73 58 86

Molded Circuits LTD1130 Melton Road, SystonLeicester LE7 8HAGreat BritainTel.: ++44 (0) 116- 260 9566Fax.: ++44 (0) 116-269 8392

In the USA:

Molded Interconnect Devices LLC250 Metro ParkRochester, NY 14623Tel.: ++1/716-272-3100

Circuit-Wise400 Sackett Point RoadNorth Haven, CT 06473Tel.: ++1/203-281-6511

Chromium Corporation2602 Spence StreetLufkin, TX 75901Tel.: ++1/409-633-6327

Metall Surfaces1814 El Rey RoadSan Pedro, CATel.: ++1/310-514-9046Fax.: ++1/310-514-9048

Crown City Platers4350 Temple City Blvd.El Monte, CA 91731Tel.: ++1/626-444-9291

MID (Molded Interconnect Devices)

MID technology is one of the most importantapplication areas for the metallization of Vectra LCP.The use of planar circuit boards manufactured fromglass fiber mat reinforced epoxy resins (FR4) has along and proven history in the electronics industry.Difficulties however arise when these are to be de-signed for 3-D circuit trees. With the aid of MIDtechnology, it is possible to manufacture 3-D struc-tures, with great freedom of design, using injectionmolding procedures. The combination of propertiesspecific to this material mean that Vectra LCP is wellqualified for MID applications. The platable Vectragrades can be used to fabricate precise, dimensionallystable and very finely detailed molded parts with circuit trees. Because of the good flowability of VectraLCP, it is especially suitable for the 2-shot process.Vectra grades that have been modified with mineralsare best used for the circuit tree framework. Glassfiber reinforced Vectra grades are favored for thesecond shot, to provide the molded part with goodstability and stiffness. The following variations of theprocedure can be used for the 2-shot method:

The PCK procedure is:

- Injection molding of the first shot with a platable,catalytically modified Vectra grade. The metallicpalladium is included in the material.

- Application of the second shot, made from a non-platable type of Vectra grade.

- The surface of the component is then etched andmetallized.

The SKW procedure is:

- Injection molding of the first shot with a platableVectra grade.

- Etching and catalysation of the surface of the firstshot with palladium.

- Insertion of the component into the mold andapplication of the second shot.

- The surface of the component is then etched andmetallized.

The 2-shot method using Vectra LCP allows thick-nesses of 0.25 mm to be realized for the track widthand the track separation. Economic saving can beachieved through the miniaturization of components,higher integration density of functional parts, reducedparts count and a high level of automation.

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Direct laser structuring is another MID technologyused with Vectra LCP. In this process, the componentis entirely made of a platable Vectra LCP. The wholesurface of the component is then metallized and coated with etch resist. A laser is used to fix the etchresist its desired circuitry and the copper covered bythe non-fixed etchant is exposed and etched away. Theplated areas remain are the desired circuitry. Thesurface is finished with, for example, gold.

11.6 Machining

Although the usual goal of designers is to produceplastic parts that can be used directly from the mold,there are times when machining is needed. Some reasons for machining are to avoid complex moldconfigurations, to achieve particularly tight tolerancesor to avoid knit lines in critical areas. Parts moldedfrom Vectra LCP machine easily when the followingpractices are followed:

- Use sharp tools- Provide adequate cooling- Allow enough chip clearance- Support the work properly

Compared to other thermoplastics, the stiffness, highthermal conductivity and low coefficient of friction ofVectra LCP promote good machinability. Vectra LCPis thermoplastic and so will melt if the machiningoperation generates too much frictional heat.

11.6.1 Prototype machining

Properties of parts molded from Vectra LCP dependon the molecular orientation created by gating, molddesign and molding conditions. Extra care should betaken when machining prototypes for evaluation. Aprototype may not have the same orientation as thefinal molded part and therefore mechanical, electricaland other properties may not necessarily be identical.In general, prototypes should be molded to the finalgeometry rather than machined from bulk stock.Surface layer properties of most polymers, includingVectra LCP, are different from their core properties. Ifmachining is unavoidable as little surface material aspossible should be removed. If the design includedmolded-in holes, drilling these holes in the prototypemakes it impossible to evaluate the effect of knit linesin the production part.

11.6.2 Tooling

Dull tools tend to scrape rather than cut yielding apoor surface finish and generating excess heat in theprocess. The best surface finishes are obtained withsharp tools, high speeds and slow feed rates. Bothmachining speed and the feed rate should be uniformand uninterrupted. Cooling allows higher cuttingspeeds especially on heavy cuts. Normally an air jet issufficient but liquids may also be used. Vectra LCP isnot attacked, crazed, dissolved or softened by any ofthe conventional cutting fluids.

In addition to having sharp cutting edges, there mustbe adequate clearance for chips. This eliminates prob-lems with clogging and interference with the cuttingoperation. When there is a choice in tool selection the machinist should pick one offering the greatestchip clearance, for example, drills with wide fluteareas or saw blades with deep gullets. Unlike someplastics, Vectra LCP containing abrasive fillers such asmineral, glass, or carbon fibers can be machined withstandard high speed stainless steel tools, though carbide tools prolong tooling life during extendedproduction runs.

11.6.3 Turning

Vectra LCP is easily turned on a lathe. Tool bits mustbe sharp and should provide a rake angle of 5 to 15°with front and side clearance angles of 15 to 0°. A tipradius of at least 1.5 mm should be used for smoothfinish cuts. Feed rates and cutting speeds for turningdepend primarily on the nature of the cut and thedesired finish. Roughing cuts may be made at the highest feasible rates without excessive heat buildup.For most work, a peripheral part speed of 20 m/min isreasonable. A smooth cut finish calls for a somewhathigher turning speed and slower feed rate. As a guideline, a 12 mm diameter rod turned with a1.5 mm tool tip radius at 100 rpm and a 0.04 mm/re-volution feed advance has an excellent surface finish.

11.6.4 Milling and drilling

Standard helical-type milling cutters are satisfactory.Two-flute end mills are preferred for greater chipclearance. Using the suggested tool speeds in Table11.6.1 Vectra LCP can be cut without a coolant. Anair jet may be desirable to keep chips from cloggingthe flutes. Feed rates should be adjusted to obtain the desired finish.

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For drilling, standard high-speed twist drills are best.While special slow spiral drills are available, theyoffer no advantages over standard drills designed formetals. Occasionally burring may occur. This can beeliminated by clamping dummy pieces of plasticabove and below the work. In any case, the workshould be firmly supported and securely held. Fordeep holes, the drill should be raised frequently(about every 6 mm of depth) to clear the drill andhole of chips. A jet of compressed air helps to dis-perse chips and cool the drill.

11.6.5 Threading and tapping

Threads may be readily cut on a lathe, using the tooland cutting conditions previously outlined.Conventional taps and dies may be used with goodresults. These may be threaded either by hand or bymachine. Use gun-nose taps when machine tapping.A speed of about 180 rpm is suggested for sizes fromUNC 10-24 through 3/8-16. The International metricequivalent sizes would be 6-1.00 to 10-1.50. A specialtap for plastics, with two flutes, is available and offerssome advantages in greater chip clearance, but it isnot essential for satisfactory results.

11.6.6 Sawing

Vectra LCP may be sawed with almost any type ofsaw. To prevent binding of the blade, however, thesaw teeth should have some degree of offset, at least0.125 mm offset per side. Coarse teeth and extra wide gullets for chip clearance are desirable for rapidcutting, while a finer blade gives a smoother edge. In general, the blade should have at least two teeth incontact with the part at all times. Bandsawing gives agood finish cut without cooling, using a blade speedof 1,000 m/min, when the part is less than 6 mm thick.

Table 11.6.1 · Tool speeds for drilling or milling

Tool diameter Tool speed(mm) (rpm)

Unfilled grades Reinforced grades

1.6 2,300 2,000

3.2 2,000 1,700

5.6 1,800 1,500

6.4 1,600 1,300

9.5 1,300 1,000

15.9 1,000 800

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12. Conversion Tables

12.1.1 Unit conversion factors

12.1.2 Tensile or flexural property conversion

12.1.3 Length Conversion

12.1.4 Temperature Conversion

Multiply byDivide by

LengthMeter (m) 0.0254 Inch (in)Meter (m) 0.305 Foot (ft)

AreaMeter2 (m2) 6.45 x 10-4 Inch2 (in2)Meter2 (m2) 0.0929 Feet2 (ft2)

VolumeMeter3 (m3) 1.64 x 10-5 Inch3 (in3)Meter3 (m3) 0.0283 Feet3 (ft3)

MassKilogram (kg) 0.454 Pound (lb)

ForceNewton (N) 4.45 Pound force (lbf)Newton (N) 9.81 Kilogram force (kgf)

PressurePascal (Pa) = Newton/meter2 (N/m2)Pascal (Pa) 6.89 x 103 lbf/in2 (psi)Megapascal (MPa) 6.89 1000 lbf/in2 (kpsi)Pascal (Pa) 9.81 x 104 kgf/cm2

Pascal (Pa) 105 Bar

ViscosityPascal.second (Pa.sec) 0.1 Poise

EnergyJoule (J) 4.2 Calorie (cal)Joules/kilogram (J/kg) 4.2 Calories/gram (cal/g)Joule/kilogram (J/kg) 2.33 x 103 BTU/lb

Strength Modulus

MPa Psi MPa Psi x 106

75 10,900 6,000 0.87100 14,500 8,000 1.16125 18,000 10,000 1.45150 21,800 12,000 1.74175 25,400 14,000 2.03200 29,000 16,000 2.32225 32,700 18,000 2.61250 36,300 20,000 2.90275 39,900 22,000 3.19300 43,500 24,000 3.48

Inches Inches Mils cm mm

1 1 1000 2.54 25.4_ 0.5 500 1.27 12.7_ 0.25 250 0.635 6.35

1/8 0.125 125 0.32 3.21/16 0.0625 62.5 0.16 1.61/32 0.0313 31.3 0.08 0.81/64 0.0156 15.6 0.04 0.4

Degrees Centigrade (°C) Degrees Fahrenheit (°F)

0 32

10 50

20 68

50 122

75 167

100 212

125 257

150 302

175 347

200 392

225 437

250 482

275 527

300 572

325 617

350 662

375 707

400 752

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NOTICE TO USERS: To the best of our know-ledge, the information contained in this publication is accurate; however, we do not assume any liabilitywhatsoever for the accuracy and completeness ofsuch information.

Any values shown are based on testing of laboratorytest specimens and represent data that fall within thestandard range of properties for natural material.Colorants or other additives may cause significantvariations in data values.

Any determination of the suitability of this materialfor any use contemplated by the users and themanner of such use is the sole responsibility of theusers, who must assure themselves that the materialas subsequently processed meets the needs of theirparticular product or use.

It is the sole responsibility of the users to investigatewhether any existing patents are infringed by the useof the materials mentioned in this publication.

Please consult the nearest Ticona Sales Office, or callthe numbers listed above for additional technicalinformation. Call Customer Services for theappropriate Materials Safety Data Sheets (MSDS)before attempting to process these products.

Vectra® LCP is not intended for use in medical ordental implants.

Celcon® and Hostaform® acetal copolymer (POM)

GUR® ultra-high molecular weight polyethylene (UHMWPE)

Celanex® thermoplastic polyester

Impet® thermoplastic polyester

Vandar® thermoplastic polyester alloy

Riteflex® thermoplastic polyester elastomer

Vectra® liquid crystal polymer (LCP)

Celstran®, Compel® and Fiberod® long fiber reinforced thermoplastics

Fortron® polyphenylene sulfide (PPS)

Celanese® Nylon 6/6 (PA 6/6)

Topas® cyclic-olefin copolymer (COC)

Encore® recycled thermoplastic molding resins

Duracon™ acetal copolymer (POM)

and Duranex™ thermoplastic polyester (PBT) are offered by Polyplastics Co., Ltd.

Fortron® is a registered trademark of Fortron Industries.

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