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Thermoplastic injection molding compounds - kbam.geampod.com Flipbook PDF
SABIC Innovative Plastics 3 SABIC Innovative Plastics is a recognized global pacesetter in engineering plastic compounds
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LNP* Verton* structural composites
Thermoplastic injection molding compounds
2 SABIC Innovative Plastics
Introduction
SABIC Innovative Plastics is a recognized global pacesetter in engineering plastic compounds. With manufacturing and sales locations throughout the world, we help our customers produce robust plastic parts because of the thermoplastic compounds we produce. Robust means improving the “effects” of base resins in areas such as structural strength and toughness — two characteristics that best describe our Verton* structural composites. Verton structural composites are thermoplastic injection molding compounds with long glass fiber reinforcement produced by a unique pultrusion process. Molded Verton components offer exceptional mechanical performance, combining rigidity and outstanding resistance to impact failures. Widely utilized across many industries, Verton structural composites bring significant value to demanding applications requiring performance that are generally beyond the reach of standard reinforced injection moldable materials. Verton structural composites provide today’s engineer with a unique balance of potential costs savings and performance. The first major Verton applications included ski binding base plates, engine cooling fans, and engine pipe clips. These applications are still in production today, updated periodically for new designs. With proven long term use at high and sub-zero temperatures, these long fiber compounds show significant advantages over standard short glass fiber reinforced compounds. When you’re selecting Verton structural composites for your next project, involve our engineering staff early in your design process to help support your search for a successful and cost-effective conclusion. Even in the most demanding metal replacement projects, SABIC Innovative Plastics can help you engineer innovative composite solutions. Standard product range • Verton MFX: structural polypropylene composites • Verton RF: structural nylon 6/6 composites • Verton RFL: low wear structural nylon 6/6 composites • Verton UF: structural polyphthalamide composites • Verton PCA: structural PC/ABS composites • Verton WF: structural PBT composites Key properties • Excellent impact resistance plus high stiffness • Good property retention at elevated temperatures • High creep resistance • Impact strength maintained at low temperatures • Excellent surface finish • Outstanding fatigue performance • Low warpage and good dimensional stability
Contents Introduction
3
Key benefits
4
Large part design
8
Metal replacement
10
Designing for equivalent performance
12
Verton MFX structural composites
13
Verton RF/PF structural composites
16
Verton UF structural composites
16
Verton PCA structural composites
17
Verton WF structural composites
18
Processing
19
Typical properties of Verton structural composites
22
SABIC Innovative Plastics 3
Key benefits
Benefit #1 Better impact resistance at any temperature. Izod impact strength of Verton* structural composites and short glass fiber products at Room temperature -40˚C
50% SG PPA Verton UF-700-10 HS 50% SG PPA Verton UF-700-10 HS
50% SG Nylon 6/6 Verton RF-700-10 EM HS 50% SG Nylon 6/6 Verton RF-700-10 EM HS
50% SG PP Verton MFX -700 -10 HS 50% SG PP Verton MFX -700 -10 HS
Impact strength (J/m)
Impact strength (ft.-lb/in.)
Verton RF structural composites
Verton RF structural composites
Falling dart impact energy for Verton structural composites at Room temperature -40˚C
Notched Izod impact strength ft.-lb./in.
3.54
312
5.83
1.38
260
4.86
0.27
136
2.54 129% improvement
The long glass fibers absorb more energy before and after fracture initiates. Fracture crack lines are forced around fiber ends. The result-higher impact values for Verton structural composites over a wide temperature range.
50% SG PPA Verton UF-700-10 HS 50% SG PPA Verton UF-700-10 HS
Number average J/m
50% SG Nylon 6/6 Verton RF-700-10 EM HS 50% SG Nylon 6/6 Verton RF-700-10 EM HS
Fiber length mm
50% SG PP Verton MFX -700 -10 HS 50% SG PP Verton MFX -700 -10 HS
The effect of fiber length on impact strength in 50% glass fiber reinforced nylon 6/6
Impact energy (J)
† Izod impact strength of Verton polypropylene actually increases by 20% at sub-zero temperatures
Impact energy (ft.-lb.)
Verton structural composites off significant improvement in impact strength.
Verton structural composites have improved multi-axial impact strength over short glass over a wide range of temperatures † No change in multi-axial impact strength for nylon 6/6 and polyphtalamide at sub-zero temperatures
4 SABIC Innovative Plastics
Benefit #2 Enhanced mechanical properties at elevated temperatures. Tensile strength at 250°F
Verton* MFX structural composites are stronger than short glass nylon at temperatures up to 200°F.
PPS 40% glass
PET 45% glass
PEI 30% glass
Nylon 6/6 30% glass
Temperature (°F)
Vernon RF-700-10 EM HS composite
Verton UF-700-10 HS composite
Tensile strength (psi)
Tensile strength (MPa)
Tensile strength (psi)
Tensile strength (MPa)
Tensile strength vs. temperature
Verton PPA and RF structural composites outperform traditional "high temperature resins" at elevated temperatures
Verton MFX-700-10 HS 30% short glass nylon 6/6 at 50% RH
Tensile modulus vs. temperature
Tensile strength (106 psi)
Tensile strength (GPa)
Tensile modulus (GPa)
Tensile modulus (106 psi)
Tensile modulus vs. temperature
Hours The tensile strength of Verton RF structural composites is not significantly affected by thermal aging.
Temperature (°F)
Verton FR-700-10 HS 40% short glass PPS 30% short glass PEI
Verton RF structural composites offer superior stiffness. Verton RF-700-10 HS at 50% RH 30% short glass nylon 6/6 at 50% RH SABIC Innovative Plastics 5
Key benefits
Benefit #3 Better dimensional stability at any wall thickness. Plague warpage (Verton* structural composites vs short fiber)
Benefit #4 Exceptional surface finish for high glass reinforced products.
Short glass materials warp at thicker sections - long fiber materials warp less due to the long random fibers in the thicker core.
2mm
3mm
4mm
Typical results for mold shrinkage of Verton structural composites at 3mm Flow (%)
Transverse (%)
Verton MFX-7008 HS
0.15
0.3
Verton MFX-700-10 HS
0.15
0.28
Verton RF-7007 EM HS
0.15
0.47
Verton RF-700-10 EM HS
0.25
0.26
Verton RF-700-12 EM HS
0.20
0.45
Verton UF-700-10 HS
0.20
0.35
6 SABIC Innovative Plastics
Verton UF-700-10 HS
Verton RF-700-10 EM HS
Verton RF-7007 -EM HS
30% SG nylon 6/6
Verton MFX-7008 HS
40% SG PP
Warpage (in)
Warpage (mm)
Surface finish comparison - Short glass fiber and long glass fiber nylon 6/6 Product
Glass contact %
60 degree gloss measurement
Average roughness (RA)
Short fiber nylon 6/6
35
40
46
Verton RF structural composite
35
84
15
Short fiber nylon 6/6
50
36
87
Verton RF structural composite
50
75
18
Product
Wear factor
COF Static/ Dynamic
50% short glass nylon 6/6
60
0.64 / 0.80
Verton RF-700-10 EM HS
30
0.59 / 0.73
Verton MFX-700-10 HS
73
0.30 / 0.34
Fewer fiber ends means better wear. † Units - 10-10 in5 min./ft.-lb -hr.
Cycles to failure
Verton* RF-700-12 EM HS structual composite (60% long glass fiber)
% Strain
% Strain
Tensile creep strain vs. time at 10,000 psi 60% short fiber nylon 6/6
Flexural strength (psi)
Flexural strength (MPa)
Benefit #5 Enhanced creep and fatigue performance particularly at elevated temperature. Flexural fatigue at 30Hz
Hours
LNP* Verton RF-700-10* EM HS structural composite 50% short glass nylon 6/6
Hours
†
At 250°F the slope of this curve is not changed indicating similar performance at 73°
Benefit #6 Virtually unmatched transverse mechanical properties. Transverse creep (4,400 psi, 185°)
Total strain (%)
Tensile modulus (GPa)
Tensile modulus (106 psi)
Transverse properties
Specimen thickness Time (hr)
Verton RF-700-10 EM HS flow Verton RF-700-10 EM HS transverse 50% SG nylon 6/6. Flow 50% SG nylon 6/6. Transverse
No difference in creep behavior in both directions Verton RF-700-12 EM HS Flow Verton RF-700-12 EM HS Transverse
†
Short fiber transverse properties reduced by 23% The modulus values of Verton RF structural composites improve in the transverse direction as wall thickness increases
††
SABIC Innovative Plastics 7
Large part design
Verton* structural composites are excellent candidates for large part applications. Several molding techniques generally recognized as suitable for the commercial production of large parts molded from Verton structural composites' include Standard Injection Molding, Injection Compression Molding (ICM), Structural Foam Molding (SFM) and Gas-Assisted Injection Molding (GAIM). These injection molding variations will be discussed in the following sections.
Prop wrench, Verton MFX structural composite
Standard injection molding Verton structural composites has been molded on presses as large as 4400 tons using hot runner systems with excellent results. These machines have large diameter screws with deep metering sections, free flow non-return valves and ample sized nozzle orifices. These massive injection units, generous sprues, runners, and gates, combined with the recommended processing conditions, all serve to maintain the original long glass fiber lengths in the finished part. The long fibers flow through these channels effortlessly and actually induce less abrasive wear on the tooling compared to short glass fiber reinforced materials. This is because there are fewer fiberglass ends which cause abrasion. Some applications for in standard injection molding include: automotive instrument panels and support systems, seating components, door substrates, battery trays, radiator supports, bumper beams, running boards and front end modules. Wall sections typically range from 0.100" (2.5mm) - 0.250" (6.35mm).
Industrial paddle fan, Verton RF structural composite
For detailed information on screw, runner, and gate design along with the recommended molding conditions, consult the processing section. Injection compression molding (ICM) ICM is a molding technique where the plastic melt is injected into a partially open cavity with injection pressures typically 50% to 75% lower than standard injection molding, depending on wall thickness, and mold open distance. The second stage clamp action closes the telescoping core and subsequently compresses and distributes the melt into the far extremities of the cavity, including any ribs or bosses. This type of low pressure molding process has been shown to be beneficial for preserving long glass fiber lengths in Verton large parts. There are two basic types of ICM, sequential and simultaneous. With sequential ICM, the reciprocating screw completes the injection and bottoms out before the clamp closes. In simultaneous, the clamp/compression stroke can be activated at any point during the injection stroke. Clamp pressures and speeds can generally be programmed or profiled during compression. Uniform packing forces are achieved across the entire part providing maximum densification. With conventional injection molding, packing is provided by the final injection pressure on the melt. Consequently, cavity pressure is much lower at the end of fill and highest near the gate, creating a significant pressure gradient and potential for warp. Using ICM, cavity pressures are more uniform throughout the part, yielding dimensional stability and less warp. Combining Verton structural composites and the ICM process delivers numerous features and resultant benefits as described in the table at right. Common applications for ICM parts are: automotive load floors, cloth or vinyl covered in-mold laminated door panels, lower kick panels and laminated sunroof/sunshades.
8 SABIC Innovative Plastics
Instrumental panel substrate, Verton MFX structural composite
(ICM) Features
Benefits
Preserves fiber length in Verton long glass fiber reinforced materials.
Generates higher physical properties and greater toughness.
Improves weld line strength.
Maintains exceptional physical properties throughout the part.
Employs significantly lower injection pressure.
Retains the initial long glass fiber length. Allows filling of large parts with less injection pressure
Reduces residual molded-in stress.
Provides less warpage and greater dimensional stability at a range of temperatures.
Creates biaxial flow patterns and uniform packing forces across the entire part.
Induces isotopic shrinkage and less part warpage. Improves falling weight impact properties.
Allows downgauged thinner walled parts without fiber damage. Wall stock of .060" (1.5 mm) is easily obtained.
Potentially lower part costs and potentially lower part weights are achieved.
Facilitates one-step molded-in cover stock laminations.
No secondary lamination/ adhesion operations are necessary resulting in lower part costs and labor savings.
Structural foam molding (SFM) Structural foam molding is a technique for producing large Verton* structural composite parts with integral solid skins, cellular cores and even higher strength-to-weight ratios. Densities are usually 65 to 90% of solid Verton and vary according to wall thickness, part design, processing conditions and the amount of foaming agent added. To obtain the greatest density reduction (20-35%), wall stock should be a minimum of 0.250" (6.35mm). A 5 to 20% density reduction can be attained on thinner walled parts, 0.125" to 0.188" thick (3.18mm - 4.76mm). Verton structural composites foam is accomplished by dry blending an endothermic Chemical Blowing Agent (CBA) with the Verton structural composite pellet in the feed hopper. During processing, the blowing agent reaches the decomposition temperature and generates CO2. The CO2 remains dissolved in the melt under pressure in the barrel. A short shot is injected into the mold allowing the screw to bottom out. The gas expands in the melt and subsequently fills and packs the cavity from within. The gas also acts as a plasticizer in the melt which reduces injection pressure and aids in the
preservation of fiber length. A shut-off nozzle, with a large orifice valve, is recommended to prevent drooling. Considering that the mold is not completely filled during injection, the resultant low cavity pressures allow Verton structural composites to be molded on oversized platen presses with huge shot capacities. Overall, this low pressure structural foam process is an effective method of maintaining fiber glass integrity in extremely large parts. Since the impact strength and toughness is considerably higher with Verton composites relative to other materials, structural foamed Verton offers superior strength-to-weight ratios for demanding, high performance, lightweight applications. The table lists the attributes of the process.
Gas assisted injection molding (GAIM) Gas-Assisted molding is another low pressure variation of standard/ conventional injection molding used to produce hollow parts. A short shot is first injected into the mold, then gas is introduced into the melt at any number of pre-designated nozzle locations. The gas pushes the melt into the extremities of the tool and hollows out the thicker sections. Gas pressure, maintained throughout the cooling time, acts as the packing pressure. The pressure is released and the part ejected. Nitrogen (N2) has become the standard gas due to its low cost and abundant supply. The features and benefits of using Verton in GAIM applications are given in the table at right.
(SFM) Features
Benefits
Employs lower injection pressures.
Retains initial long fiber length. Allows lower clamp tonnage requirements.
Reduces wall thickness.
Potentially lower part weights and part costs are achieved.
Reduces overall cycle time.
Generates more parts per hour yielding less cost per part.
(GAIM) Features
Benefits
There are two distinctive methods of introducing the N2. With the first method, known as machine-nozzle GAIM, N2 is injected, via a single gas pin, into the machine nozzle. The N2 travels through the sprue and runner system, then into the part. Hot runner manifolds are not suggested with the machinenozzle technique. In the second method, N2 is injected straight into the mold cavity using single or multiple gas nozzles. This technique, called in-article GAIM, offers the flexibility of employing several injection points to direct the gas into sections where the greatest hollowing out benefits are needed. Since the gas will seek the path of least resistance, a shut off nozzle is necessary to prevent the gas from flowing back through the machine nozzle and into the barrel.
Produces part weight while mantaining structural integrity.
Saves on material cost.
Employs significantly lower injection pressure.
Retains long fiber glass lengths in finished parts. Large parts are molded on large platen pressure with low clamp tonnage requirements.
For best results, use a gas-nozzle pin which reaches into the center of the flow channel. The nozzle pin orifice should be aligned so the gas flow is directed in line with the material melt flow. At some point during the cycle, gas pins may be retracted to allow the N2 to vent out of the part.
Structural foam molding is a low pressure process.
The use of less expensive aluminum tooling is typical.
The use of Verton structural composites with the GAIM process will not produce a clear, defined hollow gas channel. A fuzzy, fiber structure throughout the channel is normal and will vary in density depending on the grade of Verton structural composite, the glass loading, and the retained fiber length.
SABIC Innovative Plastics 9
Metal replacement
The substitution of metals by any thermoplastic is mainly driven by the need to reduce component or system costs. Cost reduction is typically obtained through parts consolidation and the elimination of secondary operations such as machining, welding, or painting. Metal replacement with thermoplastics may also provide the following additional benefits: • • • • • •
Weight reduction Corrosion resistance Chemical resistance Thermal insulation, sound damping Improved appearance / surface finish Design freedom (3D shapes)
Opportunities exist to replace diecast metals which require extensive machining or have corrosion and/or weight problems. Similarly, steel stampings having complex assemblies, deep draws or corrosion problems are also potential candidates for metal replacement.
Corrosion resistance Metal parts corrode and need replacement. These underground cable arms were being replaced every 2-3 years at Detroit Edison Power Company’s expense. Using Verton* RF structural composite, the heavy electrical cables are supported with no corrosion. Why use Verton structural composites? Verton structural composites offer an outstanding combination of stiffness and impact strength coupled with enhanced long term properties. The skeletal glass fiber structure in Verton structural composites provides enhanced mechanical properties and superior impact resistance compared to equivalent short fiber reinforced thermoplastics.
Weight savings
Bike Rack Fork Block die cast zinc, painted. Weight = 1.2 lb.
Bike Rack Fork Block molded from Verton RF structural composites.
The table below compares some of the physical and mechanical properties of the most common diecast materials, medium strength steel, Verton RF-70010 EM HS and Verton RF-700-12 EM HS.
Plastic to metal weight savings = 58%!
Material property comparison Material grade
1040
AG-40A
AZ91D
380
Verton composite RF-700-10 EM HS
Verton compostie RF-700-10 EM HS
Material description
steel
zinc alloy
magnesium alloy
aluminum -
50% LG nylon 6/6
60% LG nylon 6/6
Specific gravity
7.8
6.6
1.81
2.74
1.57
1.70
Ultimate tensile strength - psi (MPa)
75,000 (517)
41,000 (283)
33,000 (230)
46,000 (317)
38,000 (265)
38,000 (265)
Velid strength psi (MPa)
51,000 (352)
-
22,000 (150)
23,000 (159)
N/A
N/A
Tensile elongation - %
30
10
3
3.5
1.9
1.6
Modulus 106 psi (GPa)
30.0 (207)
12.3 (85)
6.5 (45)
10.3 (71)
2.25 (15.6)
2.75 (18.9)
Sheer strength psi (MPa)
-
(214)
31,000 (140)
20,000 (193)
28,000 (103)
15,000 15,500 (107)
Average maximum
N/A
500,000
200,000
100,000
1,000,000
1,000,000
Properties at 50% relative humidity
The chart shows that the ultimate tensile strength of Verton RF composites is higher than the yield strength of several diecast metals such as aluminum 380 and magnesium AZ 91D at room temperature. Verton RF composites have been selected for many demanding metal replacement applications because they offer superior strength and stiffness over equivalent short fiber reinforced thermoplastics. 10 SABIC Innovative Plastics
Cable arm stanchions: Verton RF structural composite
When replacing metals with thermoplastics, it is important to evaluate materials at the applications enduse conditions. Temperature and time dependent data should be used since the properties of reinforced thermoplastics are affected by both temperature and load duration.
Tensile modulus (GPa)
Strength (MPa)
Tensile modulus (10% psi)
Tensile modulus vs. temperature
Strength (Kpsi)
Tensile strength vs. temperature
Temperature (°F) Verton* RF-700-12 EM HS -- DAM Verton RF-700-12 EM HS -- 50% RH Verton RF-700-10 EM HS -- DAM Verton RF-700-10 EM HS -- 50% RH
Temperature (°F) Verton RF structural composites offer superior stiffness Creep strain vs. time
Strain (in/in)
Verton RF-700-10 HS at 50% RH 50% short glass nylon 6/6 at 50% RH
Time (hours) Verton RF-700-12 EM HS -- 5,000 psi (35 MPa) , 248 °F (120 °C) Verton RF-700-12 EM HS -- 5,000 psi (35 MPa), 73 °F (23 °C) Verton RF-700-10 EM HS -- 5,000 psi (35 MPa), 248 °F (120 °C) Verton RF-700-10 EM HS -- 5,000 psi (35 MPa), 73 °F (23 °C)
SABIC Innovative Plastics 11
Designing for equivalent performance
Typically, unless a metal part is over designed, design modifications are required to achieve equivalent performance in a thermoplastic part design. Although reinforced thermoplastics exhibit lower strength and stiffness than metals, it is possible to design a plastic part to provide equivalent performance to metal parts, if changes in cross-section and/or thickness can be made. For limited deflection applications, the stiffness of the metal design can be equated with the stiffness of a plastic design through the equation: EI(metal) = EI(plastic) Since thermoplastics have much lower moduli (E) than metals, the moment of inertia (I) of the plastic design must be increased to attain equivalent stiffness. The diagram below shows how the wall thickness of a part was increased and ribs were added to equate the stiffness of 16 gauge steel. Because Verton* RF-700-10 EM HS structural composite (1.57) has a much lower specific gravity than steel (7.8), the revised design with an increased wall and added ribs still yielded 50% lower weight. 16 Gauge steel sheet EI(steel) = 90 lbs-in2
Verton RF-700-10 EM HS structural composite EI Verton RF-700-10 EM HS = 115 lbs-in2
Design considerations for equating stiffness • Increase wall thickness • Add ribs • Increase section properties (Use I-beams, ribbed U-sections, hollow sections, etc.) Considerations for successful metal replacement programs • Analyze plastic design (Calculations or FEA) (modify design to meet requirements) • Ensure principle stresses in are below the material strength • Evaluate both tensile and shear stresses • Consider weldline strength of the material (avoid positioning weldlines in high-stress areas) • Apply appropriate safety factors to the materials strength and loading conditions • Follow general plastic design – Design a uniform wall – Incorporate radii – Use proper rib to wall • Simplify the mold design
12 SABIC Innovative Plastics
Automotive pedal, Verton RF structural composite
Verton* MFX structural composites
Verton MFX structural composites provide a “cost performance window” to design engineers that differentiate it from other thermoplastic compounds. The combination of value, exceptional toughness, and outstanding lightweight strength makes Verton MFX structural composites an excellent candidate for many demanding applications. Verton MFX structural composites excellent chemical resistance, low moisture absorption, and dimensional stability make it a good material of choice for harsh chemical and water environments. The Verton structural composites process technology results in pellets with exceptional fiber wet-out and glass-to-resin coupling, allowing processors to use low pressure profiles to preserve fiber length. In addition, SABIC Innovative Plastics has launched new PP and LFRT systems that are molded in color and meet automotive exterior UV (Xenon) requirements. Typical applications include, large industrial and automotive components such as front end modules, door modules, instrument panels, sunroof beams, shifter bases, load floors, running boards, bumper beams and pump housings.
Volumetric cost comparison
30% SG PPO
25% SG Acetal
30% SG PBT
33% SG nylon 6/6
Verton MFX-7008 HS(40% LG PP)
30% SG PBT
40% GMAT PP
30% SG PPO
33% SG nylon 6/6
Verton MFX-7008 HS(40% LG PP)
Strength-to-weight ratio
Cents / cubic inch
Lightweight strength
Reinforced acetal
Reinforced polyesters
Verton MFX
Reinforced PPO
Reinforced nylons @ 50% R.H.
Flexural modulus (GPa)
Flexural modulus (106 psi)
Durability and rigidity
Door module, Verton MFX structural composite
Notched Izod impact strength (ft. -lbs. per inch) Drive wheel, Verton MFX structural composite
SABIC Innovative Plastics 13
Verton* MFX structural composites
Performance at an elevated temperature is often the key requirement in selecting the proper material for an application. Verton MFX-700-10 HS and MFX-7008 HS structural composites exhibit higher modulus than several short fiber reinforced crystalline resins, even up to 200°F. The lower cost Verton MFX structural composites materials also provide better or comparable strengths up to 160°F. Verton MFX structural composites exhibit better damping properties compared to many short fiber reinforced resins. The material loss factors shown here are a measure of the material's ability to absorb energy. The higher the loss factor the better the damping properties of the material. A high material loss factor is an important material characteristic for applications requiring minimal noise and vibration. Material loss factor
30% PPO
30% SG nylon 6/6
Verton MFX-700-10 HS -- 10% LG PP Verton MFX-7008 HS --40% LG PP 20% SG nylon 6/6, 50% RH 30% SG PBT
50% LG nylon 6/6
Temperature (°F)
30% SG PBT
Verton MFX-7008 HS (40% LG PP)
Strength (MPa)
Strength (MPa)
Tensile strength vs. temperature
Modulus (MPa)
Modulus (106 psi)
Tensile modulus vs. temperature
Temperature (°F) Verton MFX-700-10 HS -- 10% LG PP Verton MFX-7008 HS --40% LG PP 30% SG PBT 30% SG nylon 6/6, 50% RH
14 SABIC Innovative Plastics
Sunroof beam, Verton MFX-14 structural composite
Verton* MFX-700-14 concentrate, is a 70% (by wt.) long glass fiber reinforced polypropylene composite. This product is specifically designed for machineside dilution using a gravimetric blender and neat polypropylene. Verton MFX-700-14 concentrate can be let down in a host of unfilled polypropylene grades to achieve specific performance requirements. It may be custom colored by using a LNP* Colorcomp* concentrate at the press. Verton MFX700-14 offers a cost effective approach to obtaining LFRT properties and provides flexibility to customize glass loading levels in a wide range of applications. Targeted application areas include large structural parts in automotive, industrial, construction and OVAD markets.
Property
Units
SI
Verton MFX-700-14 concentrate let down to 20% glass fiber content
Verton MFX-700-14 Verton MFX-700-14 concentrate let down to concentrate let down to 30% glass fiber content 40% glass fiber content
–
1.04
1.12
English Physical Specific gravity
–
1.04
1.12
1.21
1.21
Mechanical tensile strength
psi
MPa
12,400
85.4
17,000
117.6
18,000
123.9
Tensile elongation
%
%
2.4
2.4
2.2
2.2
2.0
2.0
Flexural strength
psi
MPa
19,000
130.7
23,300
153.5
24,800
171.2
Flexural modulus
psi
GPa
700,000
4.8
860,000
5.9
1,030,000
7.1
Notched Izod impact
ft.-lb./in
kJ/m2
3.2
13.3
5.0
20.8
6.7
27.7
Falling dart impact (RT)
J
J
11.7
–
14.0
–
16.4
–
Thermal HDT @ 264 psi/1.8 MPa
°F
°C
316
158
316
158
316
158
† 35 MFI homopolymer polypropylene used as the dilution resin
Typical falling dart impact and flexural performance of competing structural materials Total energy (J)
Flexural modulus (kpsi)
Verton MFX-7006 HS Verton MFX-14 concentrate † Wire-cooled 30% LGF PP 30% SGF PP 30% SGF PA 6/6 ††
†Diluted ††At
to 30% glass fiber using homopolymer PP 50% RH and 73°F
Codes: F and GF = Glass fiber, HS = Heat stabilized, LGF = Long glass fiber, M and PP = Polypropylene, PA = Polyamide, RT = Room temperature, SGF = Short glass fiber
SABIC Innovative Plastics 15
Verton* RF/PF structural composites
Verton RF/PF structural composites are nylon 6/6 and 6 compounds, respectively, tailored to satisfy the need for durable die-cast metal replacement materials. They offer excellent opportunities to help reduce both weight and cost. This family of structural composites also includes FR versions and lubricated versions to cover a wide range of segments and applications. The Verton PF structural composites are often positioned in applications where surface appearance is critical. Verton RF/PF structural composites provide the engineer with a material solution that delivers outstanding long term and high temperature behavior in demanding environments. Excellent impact strength at sub zero and elevated temperatures are key reasons for selecting Verton RF/PF structural composites. Please refer to metal replacement section for multipoint data. Typical application areas include die-cast metal replacements in safety restraint, housings, brackets, suspension components and seating. Pretensioner housing
Verton UF structural composites Verton UF structural composites are characterized by excellent strength, stiffness and creep resistance especially at elevated temperatures. As you would expect from the Verton family, they possess outstanding impact properties. They also provide exceptional chemical resistance and low moisture absorption compared to short glass reinforced nylon 66. Verton UF structural composites are easy to process and can be injection molded by conventional means. If you are looking for a metal/thermoset replacement, or your current product falls short due to more stringent requirements, Verton UF structural composites may be the solution you are looking for. The product is offered with long glass loadings of 35%, 50% and 60% to provide the right fit for a host of applications. Verton UF structural composites can deliver cost and productivity improvements in applications such as connectors in wire harnesses, automotive engine cooling, air-intake, fuel handling, transmission and brake systems.
Tensile strength (MPa) at 120°C
Verton UF-700-10 HS Verton RF-700-10 EM HS PEI 30% glass fiber PET 45% glass fiber Nylon 6/6 30% glass fiber PPS 40% glass fiber
16 SABIC Innovative Plastics
Verton* PCA structural composites
Verton PCA structural composites combine the outstanding stiffness and impact properties of the Verton structural composites with the benefits of SABIC Innovative Plastics' Cycoloy* resins. Verton PCA structural composites (long glass fiber PC/ABS) are unique amorphous composites that offer a wide range of benefits vs. typical glass-filled engineering resins. If you are looking for a metal/thermoset replacement, or your current product falls short due to more stringent requirements, Verton PCA structural composites may be the solution you are looking for. The product can be custom tailored to glass loadings of 20%, 30% and 40% to provide the right fit for a host of markets such as automotive, furniture, business equipment, and telecommunications.
Automotive • Instrument panels • MIC trim • Interior components
Verton PCA structural composites are characterized by a unique blend of strength, stiffness, creep resistance, and surface finish. As you would expect from the Verton family, they possess outstanding impact properties versus short glass reinforced analog. The product lends itself to primerless painting and can also be molded-in-color. It provides exceptional dimensional stability and is easy to process using conventional means.
Short glass acetal
Short glass polyester
Verton PCA
Short glass PPO
LNP* Verton MFX (PP)
Short glass nylons @ 50% R.H.
Flexural modulus [GPa]
Flexural modulus [10% psi]
Flexural modulus vs. impact toughness and rigidity
Office furniture • Seating • Casters • Chair bases
Notched Izod impact strength (ft.-lbs./in.)
Coefficient of linear thermal expansion
Verton MFX structural composites 20% long glass fiber
Verton PCA structural composites 20% long glass fiber
Aluminum
Copper
(in/in/°F10-6)
Telecommunications • Cell phones frames • Cell phone bases • Set top boxes
Business equipment • Monitors • Computer stations • Servers • Laser printers • Copiers
SABIC Innovative Plastics 17
Verton* WF structural composites
AG-4DA Zinc alloy
1040 Steel
380 Aluminum alloy
Targeted application areas include connectors, exterior handles, wiper arms, power distribution boxes, and other structural components.
30% SG PBT
Strength-to-weight ratio
Verton WF structural composites may provide significant cost savings to demanding applications that require a balance of impact and stiffness performance beyond the reach short reinforced composites through part consolidation. The highlights of the added value of Verton WF structural composites are low moisture absorption, exceptional impact resistance, enhanced dimensional stability, and excellent surface appearance.
Verton WF-7007
Lightweight strength
The reinforcement of thermoplastics by the addition of glass fibers to polymer matrices has long been recognized as a means of improving property performance of polymers such as strength, stiffness and toughness. Verton WF structural composites, long glass reinforced PBT, further extends the property improvement by offering enhanced mechanical performance over traditional short fiber analogs.
Verton MFX-700-14 at 20% blend
SG PC 20% short glass fiber
SG PET 20% short glass fiber
Verton PCA-F-1004
Verton WF-7007
Verton WF-700-10
Magnesium
Aluminum
Copper
Steel
(in./in./°F10-6)
Coefficient of linear thermal expansion
Targeted application opportunity: Verton WF structural composites provide exceptional toughness, low moisture absorption and good surface finish which may meet the demanding challenges of outdoor applications such as this garage door handle. 18 SABIC Innovative Plastics
Processing
Verton* structural composites have been engineered to maximize the benefits of long fiber reinforcement while maintaining the ease of processing associated with conventional short fiber reinforced compounds. Although equipment requirements and processing conditions for Verton structural composites are very similar to those of short fiber reinforced compounds, the following guidelines will assist in maintaining a balance of processing ease and part quality. Molding equipment Verton structural composites compounds can be successfully molded on most injection molding machines. Since the unique properties available from Verton structural composites result from the length of the fibers and the reinforcing framework they form, attrition during processing is detrimental to part performance. A general purpose screw will perform satisfactorily, but screws with lower compression ratios will result in less fiber breakage and therefore somewhat higher strength parts. Call our technical service department if your screw design is questionable. We can also custom design a screw for your requirements. Because of the length of Verton structural composite pellets (approximately 12 mm), bridging may be a problem in machines with small (less than 30 mm) feed throats. A free flow screw tip is highly recommended to obtain the full spectrum of properties. Furthermore it is important that the tool steels for cavity and core are hardened to 50-54 Rc. Melt temperature The exact molding conditions depend on machine configuration, tool and part design. However, the temperature should fall within the following range Cylinder temperatures (rear to nozzle) °C
°F
Verton MFX series
230-270
445-520
Verton RF series
270-295
520-560
Verton UF series
310-330
590-625
Higher melt temperatures are recommended to minimize fiber breakage, maximize flowability and to get the best surface finish. Mold temperature The following mold temperatures are recommended Mold temperature °C
°F
40-70
100-160
Verton RF series
90-120
190-250
Verton UF series
130-140
270-290
Verton MFX series
The higher mold temperatures will aid in filling and yield the best surface finish.
SABIC Innovative Plastics 19
Processing
Injection pressure and speed Injection pressure will vary with part size and configuration. High pressure and fast injection speeds will give the best surface finish, but will probably result in excessive fiber breakage. Settings should be optimized with fiber length preservation in mind. In general, injection speeds should be set low to moderate to obtain best results. Holding pressure and time The holding pressure and time should be set as a function of the part in such a way that voids, sink marks and differential shrinkage due to differential pressure in the part are avoided wherever possible. Excessively high pressures, however, can lead to inherent stresses developing close to the gate and can cause difficulties during ejection. In general 50-75% of the required injection pressure should be applied as a rough guideline. The appropriate holding time can be verified by weighing molded parts that have been produced with a step-by-step increase in the holding pressure time. In this case it is important to check whether large enough gate dimensions were designed in the tool. A minimum gate depth of .100" (2.5mm) is recommended. Back pressure In order to minimize fiber breakage a maximum back pressure of 50 psi (3.4 bar) is recommended. Screw speed For most machines, screw speeds should be 30-70 rpm, or as low as feasible so the screw recovery time is just under the part cooling time. Higher screw speeds will cause unnecessary fiber breakage. Drying All Verton* products should be dried prior to processing in order to achieve the maximum properties in the molded part. The following drying conditions are recommended for Verton: Vacuum ovens or dehumidifying driers are recommended. Too high drying temperatures or too long drying times could cause problems with discoloration, normally not affecting the mechanical properties, but should be avoided.
20 SABIC Innovative Plastics
Drying conditions Temperature °C °F Verton WF series
250
4-6
Verton MFX series
70-80 160-180
2-4
Verton RF series
80-90 180-195
4-6
Verton UF series
120- 250-260 130
6-8
80-90 180-195
4-6
Verton PCA series
121
Time hrs.
Regrind Due to fiber breakdown and its negative influence on the mechanical properties, the use of regrind is not recommended. In less critical applications the amount of regrind should not exceed 10%. Care should be taken with the moisture content of the regrind. Gates Small gates cause excessive fiber breakdown and therefore gates should be adequately sized to both minimize fiber breakdown and to fill the tool. Our general recommendation for a gate size is 0.8 times the thickness of the thickest section or a minimum of .0100" (2.5mm). Gates smaller than this can be used but may give rise to molded-in stress and voiding caused by premature freeze off. The most common and preferred gates for use with Verton structural composites are tab, sprue, diaphragm, and fan gates. These gates result in minimal shear on the material and hence reduce fiber breakdown in this region. Some success has been seen using tunnel gates in smaller parts. In this case a smooth flow path and generous radiusing is required. Pin gates are not recommended. Gate location is also important to give effective mold filling and to minimize the formation of weld lines in critical regions. A weld line occurs when separate flow fronts move towards each other and meet in the cavity, normally at the end of flow or around holes. As with short-glass fiber filled materials, Verton structural composites exhibit some reduction in mechanical properties at weld lines. To minimize this effect, weld lines should be formed using hot material. This particular area should be well vented to relieve trapped gases and therefore reduce the risk of burning. The use of mold filling analysis allows the tool designer to optimize gate location to ensure the weld lines occur in non-critical low stress areas.
Where possible, gates should feed into the thickest section of the part. To obtain favorable glass orientation, gates should be positioned to feed the longest flow path. This orientation effect will allow the maximum benefit from Verton properties in the finished part. Runners Runners must be appropriately sized to minimize fiber breakdown, undue pressure drop and premature freeze off. In general primary runners should have a minimum diameter of 0.240" (6 mm). Secondary runners may be 0.6 to 0.8 times the size of the primary runner. Cold slug wells should be provided at the end of primary and secondary runners. All runners should be adequately radiused, contain no sharp corners and be as short as possible. Runners should be balanced to obtain equal filling in a multi-cavity tool, to avoid components being over stressed resulting in poor mechanical properties and dimensions. Close tolerance parts should not be designed into family mold layouts.
Battery tray, Verton MFX structural composites
Sprues Sprues should be as short as possible and well polished and blended into the runners via smoothly radiused surfaces. The entry into the sprue bushing should be 0.020" to 0.030" (0.51-0.76mm) larger in diameter than the exit from the machine nozzle orifice. The sprue bushing should be tapered with an inclined angle of 3 to 7 degrees. The machine nozzle orifice should be as large as possible, or a minimum of 0.188” (4.78mm). A cold slug well should be provided below the sprue. Hot runners Verton* MFX and RF structural composties, because of their thermal stability and relatively wide processing temperature ranges, are being successfully molded by means of hot runner systems in multi-cavity tools. The primary sprue bushing feeding the manifold should be as large as possible, up to 0.480" (12 mm) for optimum fill rate and minimum pressure drop.
Pruners, Verton RF structural composites
The manifold flow passages should be a minimum of 0.480"–0.560" (1214 mm) and need to be smooth. Precise temperature control is required. Manifolds ends must be rounded to eliminate possible material hang-up and therefore material degradation and discoloration. In terms of heating the manifold, the use of cartridge or band heaters outside of the melt stream are recommended. Internal manifold heaters are not recommended. Externally heated open nozzle systems should be applied for all Verton structural composites. Internally heated nozzles and nozzle shut-offs are not recommended. Large orifice nozzle shut-offs may be necessary for structural foam molding.
Center hinge bracket, Verton RF structural composites
SABIC Innovative Plastics 21
Typical properties of LNP* Verton* structural composites — English units Property
Density shrinkage, flow, 24 hrs
Mold shrinkage, xflow, 24 hrs
Mold stress, break
Tensile strain, break
Tensile modulus, 1 mm/min
Tensile stress
Flexural modulus
Flexural
Standard units
ISO 1183 g/cm3
ISO 294 %
ISO 294 %
ISO 527 psi
ISO 527 %
ISO 527 psi
ISO 178 psi
ISO 178 psi
LNP Verton MFX-7006 HS
1.12
0.20
0.40
15225
2.6
1132450
22185
935250
LNP Verton MFX-7008 HS
1.22
0.15
0.30
18415
2.5
1467400
27115
1196250
LNP Verton MFX-700-10 HS
1.33
0.13
0.28
20445
1.7
2011150
31030
1615300
LNP Verton PCA-F-7004 EM
1.30
0.3
0.3
17980
2.1
1129550
20155
1010650
LNP Verton RF-7007 EM HS
1.42
0.31
0.47
31030
2.1
1735650
44805
1484800
LNP Verton RF-700-10 EM HS
1.58
0.25
0.46
34825
1.9
2665100
53650
2254750
LNP Verton RF-700-12 EM HS
1.71
0.20
0.45
37845
1.6
3375600
62785
2740500
LNP Verton UF-7007 HS
1.45
26245
1.6
1812500
38425
1624000
LNP Verton UF-700-10 HS
1.63
0.20
0.35
35525
1.5
2952200
52055
2566500
LNP Verton UF-700-12 HS
1.74
0.20
0.35
37120
1.3
3394305
57130
2958000
LNP Verton WF-7007
1.59
0.2 – 0.5
0.5 – 0.9
20445
1.3
1943000
30305
1624000
LNP Verton WF-700-10
1.70
0.20
0.4 – 0.7
23635
1
2866650
34075
2272150
Tensile strain, break
Tensile modulus, 1 mm/min
Flexural stress
Flexural modulus
Typical properties of LNP Verton structural composites — SI units Property
Density
Mold shrinkage, flow,
Mold shrinkage, xflow,
Standard
ISO 1183
24 hrs ISO 294
24 hrs ISO 294
ISO 527
ISO 527
ISO 527
ISO 178
ISO 178
units
g/cm3
%
%
MPa
%
MPa
MPa
MPa
LNP Verton MFX-7006 HS
1.12
0.20
0.40
105
2.6
7810
153
6450
LNP Verton MFX-7008 HS
1.22
0.15
0.30
127
2.5
10120
187
8250
LNP Verton MFX-700-10 HS
1.33
0.13
0.28
141
1.7
13870
214
11140
LNP Verton PCA-F-7004 EM
1.30
0.3
0.3
124
2.1
7790
139
6970
LNP Verton RF-7007 EM HS
1.42
0.31
0.47
214
2.1
11970
309
10240
LNP Verton RF-700-10 EM HS
1.58
0.25
0.46
256
1.9
18380
370
15550
LNP Verton RF-700-12 EM HS
1.71
0.20
0.45
261
1.6
23280
433
18900
Tensile stress, break
LNP Verton UF-7007 HS
1.45
181
1.6
12500
265
11200
LNP Verton UF-700-10 HS
1.63
0.20
0.35
245
1.5
20360
359
17700
LNP Verton UF-700-12 HS
1.74
0.20
0.35
256
1.3
23409
394
20400
LNP Verton WF-7007
1.59
0.2 - 0.5
0.5 - 0.9
141
1.3
13400
209
11200
LNP Verton WF-700-10
1.70
0.20
0.4 - 0.7
163
1
19770
235
15670
22 SABIC Innovative Plastics
Typical properties of LNP* Verton* structural composites — English units continued Property
Units
Izod impact,
Izod impact,
Izod impact,
CTE, -40°C
CTE, -40°C
HDT/Af,
unnotched
notched
notched
to 40°C,
to 40°C,
1.8 MPa
80*10*4 +23°C
80*10*4 +23°C
80*10*4 -40°C
flow
xflow
Flat w 80*10*4
ISO 180/1U ft-lbs/in2
ISO 180/1A ft-lbs/in2
ISO 180/1A ft-lbs/in2
ISO 11359-2 x 10-5 1/°F
ISO 11359-2 x 10-5 1/°F
sp = 64mm ISO 75/Af °F
LNP Verton MFX-7006 HS
23
9
LNP Verton MFX-7008 HS
24
12
2.6
4.6
320
LNP Verton MFX-700-10 HS
31
14
1.9
2.5
320
LNP Verton PCA-F-7004 EM
20
9
8
273
14
12
486
LNP Verton RF-7007 EM HS
316
LNP Verton RF-700-10 EM HS
42
21
18
1.0
3.7
487
LNP Verton RF-700-12 EM HS
49
26
20
0.9
2.9
486
LNP Verton UF-7007 HS
11
518
LNP Verton UF-700-10 HS
18
529
LNP Verton UF-700-12 HS
25
541
LNP Verton WF-7007
18
13
LNP Verton WF-700-10
28
19
20
2.0
3.6
448
1.0
2.3
437
Typical properties of LNP Verton structural composites — SI units continued Property
Izod impact,
Izod impact,
Izod impact,
CTE, -40°C
CTE, -40°C
HDT/Af,
unnotched
notched
notched
to 40°C,
to 40°C,
1.8 MPa
80*10*4 +23°C
80*10*4 +23°C
80*10*4 -40°C
flow
xflow
Flat w 80*10*4
ISO 180/1U
ISO 180/1A
ISO 180/1A
ISO 11359-2
ISO 11359-2
ISO 75/Af
kJ/m2
kJ/m2
kJ/m2
x 10-5 1/°C
x 10-5 1/°C
°C
sp = 64mm
Units
LNP Verton MFX-7006 HS
49
18
LNP Verton MFX-7008 HS
50
25
4.61
8.27
160
158
LNP Verton MFX-700-10 HS
66
29
3.37
4.58
160
LNP Verton PCA-F-7004 EM
41
18
17
134
LNP Verton RF-7007 EM HS
29
25
LNP Verton RF-700-10 EM HS
89
45
38
1.86
252 6.73
253
LNP Verton RF-700-12 EM HS
102
54
43
1.70
5.30
252
LNP Verton UF-7007 HS
23
270
LNP Verton UF-700-10 HS
38
276
LNP Verton UF-700-12 HS
52.5
283
LNP Verton WF-7007
37
27
-
3.62
6.40
231
LNP Verton WF-700-10
59
40
43
1.85
4.14
225
SABIC Innovative Plastics 23
Contact us Americas Headquarters SABIC Innovative Plastics One Plastics Avenue Pittsfield, MA 01201 USA T 800 845 0600 T 413 448 5800 F 413 448 7731 European Headquarters SABIC Innovative Plastics Plasticslaan 1 PO Box 117 4600 AC Bergen op Zoom The Netherlands T +31 164 292911 F +31 164 292940 Technical Answer Center T 0800 1 238 5060 * toll free (if mobile disruption + 36 1 238 5060) Pacific Headquarters SABIC Innovative Plastics 1266 Nanjing Road (W) Unit 902-907, Plaza 66 200040 Shanghai China T +86 21 3222 4500 F +86 21 6289 8998
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