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86 views20 pages

Ryton PPS Processing Guide en v2.1 0

Uploaded by

Vitor Segnini
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Ryton

Ryton® PPS
Processing Guide

SPECIALTY
POLYMERS
Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ryton® Polyphenylene Sulfide (PPS) . . . . . . . . . . . . 5

Processing Requirements . . . . . . . . . . . . . . . . . 6
Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Forced Draft Oven . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dehumidifying Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stock Temperature & Barrel Profile . . . . . . . . . . . . 6
Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injection Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mold Temperature Effects . . . . . . . . . . . . . . . . . . . . 7
Crystallinity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Polymer Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Surface Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . 8
Summary of Mold Temperature Effect . . . . . . . . . . 9
Start Up and Shut Down Procedures . . . . . . . . . . . 9
Other Processing Considerations . . . . . . . . . . . . . . 9
Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Check Ring Function and Cushion . . . . . . . . . . . . . . 10
Drool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Screw, Barrel and Mold . . . . . . . . . . . . . . . . . . . . . 11

Equipment Requirements . . . . . . . . . . . . . . . . 12
Mold Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Equipment for Managing Drool . . . . . . . . . . . . . . . 12
Reverse Taper Nozzles . . . . . . . . . . . . . . . . . . . . . . . 12
Positive Action Shut-off Nozzles . . . . . . . . . . . . . . . . 12
Vented Barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Resin Drying Equipment . . . . . . . . . . . . . . . . . . . . 13
Hot Runner Systems . . . . . . . . . . . . . . . . . . . . . . . 13

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Appendix A – Ryton® PPS Compound Typical
Processing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Appendix B – Auxiliary Equipment . . . . . . . . . . . . 15
Appendix C – Injection Molding Ryton® PPS
Trouble-Shooting Guide . . . . . . . . . . . . . . . . . . . . 15

Ryton® PPS Processing Guide /3


4 \ Ryton® PPS Processing Guide
Introduction

Ryton® Polyphenylene Sulfide (PPS) It is impossible to review all of the processing difficulties
that might arise, or the procedures to correct these
The information presented in this processing manual is
problems, in one manual. Instead, a practical and
intended to assist designers and customers in the use of
expedient approach to the processing requirements for
Ryton® PPS engineering thermoplastics. The processing
successful use of Ryton® PPS compounds is offered here.
requirements discussed are topically organized to enable
the reader to apply Ryton® PPS to his specific needs and
equipment.

Ryton® PPS Processing Guide /5


Processing Requirements

Unlike many other high-performance plastics, Ryton® PPS devices. On the other hand, temperatures up to 343 °C
compounds are remarkably easy to process. Marketing (650 °F) can help fill complex or thin-walled parts. Typical
surveys indicate that the processibility of Ryton® PPS is temperature ranges are shown below.
one of its principal benefits to users. The molder has a wide
Stock temperatures
“window” of molding parameters that yields dimensionally
accurate and reproducible parts. Furthermore, Ryton® < 304 ºC (< 580 ºF) 304 – 343 ºC (580 – 650  ºF) > 343 ºC (> 650 ºF)
PPS performance is much less sensitive to molding Don’t use Preferred Use caution
parameters than competitive engineering thermoplastics.
As melt temperature is varied within the specified range,
In general, Ryton® PPS compounds are easily processed
some minor changes occur in the physical properties.
on conventional reciprocating screw injection molding
These properties vary due to changes in crystallinity,
machines using molding practices standard for filled
glass fiber orientation, and melt viscosity. Tensile strength
engineering thermoplastics. The following guidelines have
increases slightly with increasing stock temperature. lzod
proven successful for optimal processing.
impact strength, flexural strength, flexural modulus and
heat distortion temperature exhibit insignificant changes
Drying with varied melt temperatures.
All Ryton® PPS compounds are more readily processed
Figure 1 shows the effect of melt temperature on spiral
if dried thoroughly before molding. The resin itself is
flow of Ryton® R-4-200NA. Appendix A lists typical
essentially not hygroscopic, but some mineral fillers may
temperature ranges for all zones of the barrel and nozzle
be, so drying is particularly important for mineral filled
for different Ryton® PPS compounds.
compounds. The following procedures have proven
effective. Figure 1: Effect of melt temperature on spiral flow of
Ryton® R-4-200NA
Forced Draft Oven
The Ryton® PPS molding compound should be placed
762
in trays no deeper than 50 mm (2 inches) and dried at (30)
135 – 163 °C (275 – 325 °F) for 2 to 3 hours. Longer drying 635
(25)
Spiral flow [mm (in)]

times are not harmful, but temperatures above 260 °C 508


(500 °F) can reduce melt flow values over a period of time. (20)
381
(15)
Dehumidifying Dryer 254
(10)
The size of the dryer should allow for drying times of 2
127
hours with 149 °C (300 °F) inlet air temperature having a (5)
–40 °C (–40°F) dew point. 0
260 287 316 343 371
NOTE: Simple convection ovens are not recommended, (500) (550) (600) (650) (700)
because no escape for moisture-laden air from the oven Melt temperature [°C (°F)]
cavity is normally provided.
Injection Pressure
Stock Temperature & Barrel Profile First stage or injection fill pressure should be set 200 to
Due to their inherent thermal stability, Ryton® PPS 400 psig higher than the peak pressure obtained at the
compounds can be processed at stock temperatures end of part fill and transfer to pack pressure. This will
ranging from 304 – 343 °C (580 – 650 °F). Over that range, allow the injection rate to be the controlling parameter
spiral flow increases more than 30 %. This ability to control during part fill and should help minimize any part variation
flow can help packing and therefore improve physical because of material lot-to-lot differences. To ensure
properties. proper packing, the second stage pressure (Pack or
Hold Pressure) should be the maximum possible. This is
For most parts, the optimal stock temperature is between
especially true since the amount of molten plastic packed
315 – 343 °C (600 – 620 °F). This range ensures good
into the cavity can affect the physical characteristics of
flow and fluxing of glass and mineral fillers which will
the material. Substantially under-packed parts may exhibit
minimize screw, check ring, and barrel wear. In some
poor mechanical strength.
cases, however, temperatures outside this range can
be beneficial. For example, stock temperature from The pack pressure used when molding Ryton® PPS
304 – 327 °C (580 – 620 °F) can help minimize drool or compounds will determine the degree of molecular
prevent solder wash while encapsulating certain electronic packing obtained, and therefore the uniformity of polymer

6 \ Ryton® PPS Processing Guide


distribution. Well-packed parts molded with higher pack 88 – 127 °C (190 – 260 °F) range yields unpredictable
pressures have consistent part weight and surface finish, crystallinity and should be avoided.
with fewer voids, less warp and lower shrinkage. For these
As illustrated in Figure 2, parts shot in molds below 88 °C
reasons, the maximum pack pressure should be used.
(190 °F) develop little crystallinity while parts from molds
at 149 °C (300 °F) develop a crystallinity index of over 50.
Injection Rate However, the interior of thick sections may retain sufficient
Part size, wall thickness and gate size all play a large heat to develop most of the crystallinity when shot in a
role in determining the proper injection rate. Typically the 88 °C (190 °F) mold. Thin sections cool more rapidly, so
injection rate should be medium to fast or the maximum mold temperatures of 135 – 149 °C (275 – 300 °F) may
possible without trapping gas and/or causing molded-in be required for substantial crystallization. Continued
stresses. Varying the injection rate will affect appearance crystallization becomes progressively slower as it
properties such as surface gloss. Typically, the best approaches the ultimate degree of crystallinity.
overall part appearance is obtained with fast injection
rates. A faster injection rate results in a more polymer Figure 2: Effect of mold temperature on crystallinity
rich surface layer. Also, faster rates help avoid premature 100
cooling of the melt front, which will cause irregular surface 90
replication and poor weld line strength. 80
Annealed at 260 °C (500 °F)

Crystallinity index
70
For thick-walled parts, slow injection rates result in more 60
Annealed at 204 °C (400 °F)
uniform polymer distribution. This will produce parts with a 50
low level of molded-in stress, and thus reduced part warp. 40
Slower rates can also reduce burning in poorly vented 30
areas. However, a poor surface finish may occur. 20
10
In any case, it is essential that the combination of pressure
0
and rate yield a fully packed part. Proper part packing
38 66 93 121 149 177 204
may be evaluated by monitoring part weight and obtaining (100) (150) (200) (250) (300) (350) (400)
densities close to the data sheet values. Mold temperature °C (°F)

In some situations, the shortest possible cycle time


Mold Temperature Effects
may be desirable, or the use of a hot mold may prove
The following paragraphs discuss the effects of different
impractical. Cold molded parts can be made crystalline
mold temperatures on physical properties directly related
by post mold annealing at temperatures above the glass
to crystallinity. This will aid in determining the mold
transition temperature. Since the rate of crystallization
temperature for specific end use parts.
depends on temperature, the time required to reach
maximum crystallinity depends on the temperature to
Crystallinity
which the parts are exposed. Crystallization will begin
Ryton® PPS can be molded in either an amorphous or
to occur as the annealing temperature reaches the
a semi-crystalline state. Ryton® PPS will crystallize at
glass transition temperature of 88 °C (190 °F). The rate of
temperatures above its glass transition temperature of
crystallization will increase as the temperature increases
88 °C (190 °F). Mold temperature largely determines the
from that point.
crystallinity of Ryton® PPS parts, and thus affects the
part’s final physical properties and appearance. When annealing typical injection molded parts, experience
shows ultimate crystallinity is reached in 1 – 2 hours at
When Ryton® PPS compounds are molded in a cold mold
204 – 232 °C (400 – 450 °F). It will typically require 4 – 6
below 88 °C (190 °F), the polymer is quenched below its
hours at an annealing temperature of 121 °C (250 °F).
glass transition temperature so quickly that the polymer
matrix is frozen in the orientation of the injected plastic. NOTE: Annealing may cause some dimensional changes
These “cold molded” parts have very low crystallinity and (shrinkage and potential warping) as well as some
are generally considered amorphous. differences in surface appearance due to the smaller
crystalline structure.
Mold temperatures from 135 – 149 °C (275 – 300 °F) will
produce parts that are highly crystalline and, as illustrated To summarize, the most convenient way to obtain parts
in Figure 3, do not increase cycle time substantially. with high crystallinity is to mold them in a hot mold. These
Ryton® PPS crystallizes so rapidly that a hot mold parts will be dimensionally stable at elevated temperatures,
will produce dimensionally stable parts able to resist and require a cycle time only marginally longer than
dimensional changes even at elevated temperatures. those obtained with a cold mold. Cold molded parts
are considered amorphous and have somewhat better
NOTE: The crystallinity increases very rapidly between
mechanical properties, but are not as dimensionally stable
the cold and hot molding conditions. Therefore, the
at temperatures above the glass transition temperature.

Ryton® PPS Processing Guide /7


Cycle Time Figure 4: Cold mold vs. hot mold part appearance
Figure 3 illustrates the effect of mold temperature and part
thickness on cycle time for a typical glass filled Ryton®
PPS compound. Cycle times will be at least 10 – 30 % less
with glass and mineral filled compounds.

Figure 3: Effect of mold temperature on cycle time


of Ryton® PPS
Cycle time

Cold mold Hot mold


135°C (275°F)
38 – 88 ºC (100 – 190 ºF) 135 – 149 ºC (275 – 300 ºF)
38°C (100°F)
• Rough and mottled surface • Duplicate mold surface
• Low level of crystallinity • High level of crystallinity
1.6 3.0 6.4 • Less dimensional stability • Increased dimensional
(0.062) (0.120) (0.250) • Shorter cycle stability
Part thickness [mm (inch)]
• Less external heat on mold • Longer cycle
Polymer Flow • Molds must be heated
and insulated
In addition to its effect on polymer crystallinity, the mold
temperature can affect the flow of Ryton® PPS in the Mechanical Properties
mold. With all other conditions equal, the spiral flow of
Since Ryton® PPS’s crystalline lattice structure restricts
Ryton® PPS increases about 10 % as mold temperature
movement in the polymer matrix, molded parts can resist
increases from 79 – 135 °C (175 – 275 °F).
certain external forces and remain dimensionally stable.
Surface Appearance As the mold temperature is increased, more crystalline,
stable, and rigid parts are produced, as indicated by
Mold temperature has a dramatic effect on the surface
an increase in flexural modulus and heat distortion
appearance of a part. As shown in Figure 4, the sample
temperature.
molded in a hot mold duplicates the mold surface
accurately and has a polymer rich surface. However, the Parts molded in either hot molds or cold molds with
cold molded surface is rough and mottled with variations subsequent annealing generally develop adequate
in color. This is due to rapid freezing of the glass and crystallinity to resist distortion at temperatures up to
polymer at the surface of the mold. 260 °C (500 °F). If the part is heat treated at 271 °C (520 °F)
for 4 hours, heat distortion temperatures above 260 °C
(500 °F) are possible. At these conditions, slight curing
of the resin may occur in addition to crystallization. Parts
may require annealing at a lower temperature prior to heat
treatment to avoid blistering.

Amorphous parts are not as restricted by the crystalline


lattice, so the matrix may align or orient itself somewhat
to bear certain types of stresses. Though the crystalline
matrix is very strong, it is not as strong as the polymer
chain itself, so amorphous polymers exhibit slightly higher
flexural and tensile strengths. This effect is most dramatic
in response to sudden, concentrated stress, like impact.
Impact strength is substantially higher in amorphous
Ryton® PPS.

8 \ Ryton® PPS Processing Guide


Summary of Mold Temperature Effect injection pressure should be raised to ensure velocity
control during injection. Adjust injection speed to obtain
This is a basic summary of the effects of mold
satisfactory fill time. Adjust shot size and cut-off transfer
temperature on the properties of Ryton® PPS parts:
position to obtain a part that is 95 to 99 % full at transfer
Cold mold Hot mold with the desired injection speed. Gradually add pack
below 88 ºC (190 ºF) above 135 ºC (275 ºF) and hold pressure until the part is fully packed, leaving a
Amorphous part Crystalline part cushion of 2.54 – 6.35 mm (0.1 – 0.25 inches).
Best physical properties Best overall appearance
Final adjustments to the stock temperature, injection rate,
Less shrinkage Best thermal and
(directly out of mold) dimensional stability
times, and pressures can then be made to minimize cycle
Mottled/grainy surface appearance
time. Each variable should be adjusted independently,
however, to allow for determination of that parameter’s
effect.
Start Up and Shut Down Procedures
After the mold and barrel are heated to the molding After molding with Ryton® PPS, the barrel should be
temperature, any previous polymer should be purged from purged with the same fractional melt index HDPE. Finally,
the barrel with low melt index high density polyethylene the mold should be sprayed with a good rust-inhibitor
(HDPE). The following conditions should be checked prior type lubricant.
to injecting Ryton® PPS into the mold. CAUTION: Off-gas products produced during
molding can be irritants to mucous membranes.
Start Up/ Typical
Shut Down on Cycle Adequate ventilation of the molding shop area is
strongly recommended when injection molding
Clamp tonnage Maximum possible Maximum possible
with mold with mold Ryton® PPS compounds.

Melt temperature 304 – 343 °C 316 – 329 °C


(580 – 650 °F) (600 – 625 °F) Other Processing Considerations
Injection rate Slow to medium Medium to fast Regrind
Injection pressure, Medium 200 – 400 psig With Ryton® PPS compounds, all runners, sprues, and
1st stage > peak reject parts can be reused with insignificant effect on
Injection pressure, Low or zero High as possible
properties. Flow rate change is minimal if regrind levels are
2nd stage kept below 30 – 35 %. Since Ryton® PPS compounds are
inherently flame retardant, regrind is as flame resistant as
Injection time, 3 to 7 seconds 0.5 to 2 seconds
1st stage virgin material.

Injection time, 10 to 15 seconds 5 to 12 seconds Regrind levels up to 35 % can be utilized, with 25 %
2nd stage maximum for UL applications. However, tests have been
Screw speed Medium Medium run using 100 % regrind. After 7 passes through an
(typ. 100 rpm) injection molding machine, specimens retained 85 % of
Back pressure Less than 50 psig 50 to 100 psig mechanical properties and nearly 100 % of their electrical
properties. Table 1 shows the results of one such
Mold temperature 135 – 149 °C 135 – 149 °C
experiment with different Ryton® PPS compounds.
(275 – 300 °F) (275 – 300 °F)
Like other glass reinforced and mineral filled materials,
Mold release is only needed until the machine is on cycle.
Ryton® PPS compounds should be granulated using
Mold cavities should be coated with a high temperature
carbide blades or blades made from wear resistant
mold release, particularly in ribs and bosses. High
steel that is hardened. A low speed, screenless type
temperature fluorocarbons have proven to be effective.
granulator typically produces regrind with the best yield.
Once these guidelines have been followed, short shots If regrind is stored at ambient temperatures for extended
should be made to observe fill patterns and prevent periods, it should be dried before molding. (Processing
potential flashing. After the first few short shots, Requirements – Drying).

Ryton® PPS Processing Guide /9


Table 1: Effects of regrind on flow, mechanical and electrical properties
Ryton® R-4-200NA Ryton® R-7-120NA
Property Unit Virgin Compound 100% Regrind Virgin Compound 100% Regrind
Tensile strength ksi 28 23 19 13
Flexural strength ksi 39 36 32 20
Insulation resistance ohms 6 · 1010 1.6 · 1011 5 · 1010 1.6 · 1011
Spiral flow * mm (inch) 472 (18.6) 508 (20.0) 324 (12.75) 333 (13.1)

*Spiral flow thickness – 1.5 mm (0.06 inch), 335 ºC (635 ºF)

Purging Processing
Before and after molding Ryton® PPS, the barrel should In many situations, thorough drying will eliminate drool
be purged thoroughly. To ensure effective cleaning, completely. However, if drool persists after drying, certain
the barrel temperature should be the same as when processing conditions can be manipulated to control it
processing Ryton® PPS. A fractional melt flow HDPE (e.g., effectively. First, the barrel temperatures should be kept
a melt index of 0.5) is ideal for removing any previous as low as possible, but not below the 304 °C (580 °F) limit.
polymer as well as for purging after molding with Ryton® Operating below this limit has the effect of reducing barrel
PPS. Low melt flow HDPE is preferred because it can and screw life as well as not allowing good fluxing of the
withstand typical Ryton® PPS barrel temperatures for a mineral and/or glass prior to injection into the mold.
short period of time.
Second, melt decompression or “suck-back” can often
Check Ring Function and Cushion help prevent drool. Most injection machines are equipped
with this feature to pull the screw back in the barrel,
It is essential that the injection molding machine have a fully
thus decompressing the melt forward of the screw. The
functional check ring, which is preferred to a ball check due
necessary amount of decompression must be determined
to its long-term reliability. This ensures the machine’s ability
by trial and error, as it will vary depending on the
to maintain a cushion and fully pack the parts and not to
compound, shot size, barrel temperature, etc.
allow any plastic to back up around the screw.
Nozzle temperature is often the key to controlling drool.
Drool Since abrasive wear is not a serious concern in the nozzle,
Ryton® PPS is a highly crystalline polymer with a its temperature can be reduced below the 204 °C (580 °F)
sharply defined melting point which results in a rapid limit. The nozzle tip contacts the mold and thus is the
transformation from a solid to a low viscosity melt. With coolest point because it transfers heat to the mold itself.
certain compounds, the viscosity of the melt is low In most cases, the nozzle temperature can be cooled
enough to discharge from the nozzle without injection enough to prevent drool without freezing off the nozzle
pressure. This phenomenon is known as drool. tip. This temperature also varies depending on the barrel
temperature, nozzle size and type, mold temperature, etc.,
There are a number of ways to minimize or eliminate
and must be determined by trial and error. A temperature
drool. The most common methods include drying the
between 293 – 310 °C (560 – 590 °F) usually proves
compounds, applying specialized processing techniques,
successful.
and using special equipment such as positive shut-off and
reverse taper nozzles. Reverse taper nozzles like those used for processing
nylon compounds work well for Ryton® PPS. In these
Drying nozzles the flow path narrows down to a small diameter
For Ryton® PPS compounds, surface moisture is typically for a distance of 6.35 – 25.4 mm (0.25 – 1.0 inches). In many
an issue. If stored in a humid environment, the resins cases, the narrowed flow path restricts flow enough to
may pick up some surface moisture and require drying prevent drooling, especially when the nozzle temperature
techniques. When heated in the barrel, the moisture is reduced. These nozzles can be obtained from most
vaporizes and the resulting steam pressure can force suppliers of plastic processing equipment for about the
molten compound out of the nozzle. Many mineral fillers same price as ordinary general purpose nozzles.
are hygroscopic and can absorb moisture from the
atmosphere. Therefore, the mineral filled compounds are Special equipment
more susceptible to moisture driven drool. Ryton® PPS See Equipment Requirements – Equipment to Manage
glass and mineral filled compounds should always be Drool for a complete description of the most effective
dried for 2 – 3 hours at 135 – 163 °C (275 – 325 °F). In some methods of preventing drool.
cases the glass-fiber-only reinforced compounds can be
molded without drying, but the best practice is to dry all
compounds.

10 \ Ryton® PPS Processing Guide


Machines Many mold steels are able to resist the erosion caused by
fillers. The choice of mold steel is dictated by economics,
Ryton PPS compounds can be easily processed on
®

location within the mold and life expectancy required.


conventional reciprocating screw injection molding
Since new coatings and protective treatments are
equipment. Both sprue and parting line injection machines
continually introduced, a single “best” choice has not
are widely used. Most parts require 2.5 – 4.0 tons of clamp
been listed. More complete information on mold steels,
force per square inch of the projected surface area of
coatings, and wear are included in the Ryton® PPS Design
the part. A temperature controller on the nozzle is helpful
Guide.
when making adjustments to control drool.
After an extended time of processing, mold surfaces,
Mold temperature is crucial in controlling crystallinity and
especially vent areas can accumulate polymer residue on
thus the high temperature performance of Ryton® PPS.
the surface of the mold. Commercially available spray-on
Mold heating equipment should be capable of maintaining
mold cleaners typically work well enough to remove this
mold temperatures at 135 – 149 °C (275 – 300 °F) by
residue. It has been found that Slide Products Inc., Slide
the use of electric cartridges, hot oil or high-pressure
Mold Cleaner Plus Degreaser III and Slide Resin Remover
water. Each type is capable of achieving desired mold
“Stripper” are good products for mold cleaning. Along
temperatures; however, the hot oil and high pressure
with the cleaning products a plastic scouring pad may
water systems provide the added benefit of being able to
be useful to scrub the mold. In addition, a semi-chrome
add to, as well as remove heat from the mold. Appendix B
polish on the end of a cotton swab can get into difficult to
lists manufacturers of all three types of temperature
reach areas.
control equipment.
A more modern and less labor intensive approach for
Screw, Barrel and Mold mold cleaning is the utilization of ultrasonic cleaning baths.
All highly-filled engineering plastics can cause wear on A mild detergent in the ultrasonic bath will typically provide
conventional injection molding screws, barrels and molds a clean mold surface and can clean residue from difficult
constructed of steel with insufficient hardness. Of the to reach areas. More details of ultrasonic cleaning of
factors contributing to wear, fiberglass and mineral filler molds are available from commercial suppliers. After any
content are the most important. For example, fiberglass mold cleaning and before mold storage, mold surfaces
has a Mohs hardness of 5 – 7 compared to common should be sprayed down with a good rust inhibiting
tool steels with a hardness of 4. Certain processing lubricant or shield.
parameters can be adjusted to minimize abrasion. Stock
temperatures above 327 °C (620 °F) will help the molten
polymer lubricate the fillers through the injection unit.
Even so, special consideration should be given to the
wear-resistance of screw, barrel, check ring and nozzle
materials. A general recommendation is Xaloy ® 802 or
CPM 10V for the barrel liner and Stellite®, Colmonoy ® 56
or CPM 9V flighted screws.

The mold itself is also affected by the abrasive nature of


glass and particulate mineral fillers. The mold cavity and
core finish play an important role in the tool longevity,
and machining marks in these areas have been shown to
accelerate wear. Therefore, a 0.0001 mm (4 microinch) or
better finish is recommended for high-production cores
and cavities. Gates should be hardened and replaceable,
if possible, to obtain greatest mold longevity.

Ryton® PPS Processing Guide / 11


Equipment Requirements

Mold Plating material is injected, the injection pressure forces the shut-
Mold plating is an excellent way to improve the service off components open only far enough for material to pass
life of a mold made of insufficient quality steel. To ensure through. High pressure is maintained on the components
good plating, the most important variable is the condition as the compound is forced through a very small opening
of the substrate surface. The importance of a clean, at very high velocity. As a result, the abrasive action of the
highly-polished surface cannot be over-emphasized. A glass fiber and mineral fillers can wear the components
more complete description of mold plating is included very quickly if hardened materials are not used.
in the Ryton® PPS Design Guide. The following are Note: Shut-off nozzles incorporating an internal
coatings proven to be effective for use with Ryton® PPS spring have limited utility. The springs lose their
compounds. stiffness at the high stock temperatures used in
• Electroless nickel plating processing Ryton® PPS (up to 343 °C (650 °F)).
• Slow deposition chrome (dense chrome)
Externally actuated shut-off nozzles operate on an entirely
• Nye-carb plating different principle. An actuating mechanism, triggered
by the machine cycle sequence, opens the nozzle upon
Equipment for Managing Drool injection. This allows material to flow freely through
If large quantities of Ryton® PPS compounds are to be the nozzle into the mold. After the injection sequence,
processed, an investment in specific equipment can be the mechanism reverses, positively shutting off the
worthwhile in preventing drool. nozzle. The actuating mechanism can be a hydraulic
cylinder properly tied to the machine’s hydraulic system,
Reverse Taper Nozzles an electrical solenoid keyed off the electrical control
Many molders already have special nozzles for processing system, or a pneumatic cylinder triggered electrically or
nylon compounds. In these reverse taper nozzles, the mechanically.
flow path narrows down to a small diameter for a distance Externally actuated shut-off nozzles are available from:
of 6.35 – 25.4 mm. (0.25 – 1.0 inch). These have proven
advantageous in processing Ryton® PPS compounds. Xaloy Inc. Northern Supply Co.
In many cases, the narrowed flow path restricts flow 102 Xaloy Way 1901 Oakcrest Ave.
enough to prevent drooling, especially when the nozzle Pulaski, VA 24301 St. Paul, MN 55113
temperature is reduced as previously described. These +1 540-994-2269 +1 651-638-0888
nozzles can be obtained from most suppliers of plastic +1 800-773-1356 (toll free) +1 800-365-6565 (toll free)
processing equipment for about the same price as www.xaloy.com www.northernsupply.com
ordinary general purpose nozzles.
Vented Barrels
Positive Action Shut-off Nozzles
Some injection molding machine manufacturers offer
To date, an externally actuated, positive action shut-off vented barrels for their equipment. These are reported
nozzle is the only “fail-safe” cure found for drool. There are to provide advantages in processing Ryton® PPS
many different types of shut-off nozzles available. These compounds by preventing drool and eliminating the need
can be categorized into two basic types: spring loaded to dry the compounds. The barrels have a vent port cut in
and externally actuated shut-off nozzles. Different types the barrel, which permits gasses to escape from the barrel
of spring loaded nozzles have been tested with moderate while the compound is first melted and plasticized. Vented
success. With this type of nozzle, spring pressure is barrels also require a special screw.
maintained on the shut-off components at all times. When

12 \ Ryton® PPS Processing Guide


Resin Drying Equipment A hot runner system is typically more difficult to start
up and control than a conventional 2-plate or 3-plate
The Ryton PPS resin itself absorbs very little atmospheric
®

mold when running Ryton® PPS. Extra time and effort


moisture. Some Ryton® PPS compounds, however,
is typically required due to balancing the temperature
include mineral fillers which are hygroscopic and therefore
between several cavities to prevent freezing off or
should be dried. The compounds can be dried effectively
drooling.
using either forced draft ovens or dehumidifying dryers
with plenum hoppers (see Processing Requirements Temperature control at the gate is very important when
– Drying). Appendix B lists a few of many auxiliary selecting a hot runner system for processing Ryton® PPS
equipment manufacturers of drying equipment. successfully. Utilizing a mechanical type hot runner
system with a valve gate shut-off will reduce problems
Hot Runner Systems with drool and shorten start-up time.
Hot runner systems work on the principle of keeping Hot runner systems help lower costs by reducing material
the plastic material fluid up to the point of injection. The requirements and eliminating regrind. However, hot
material flows from the nozzle through a hot manifold and runner systems typically are more expensive to purchase
bushings that keeps the material plasticized by typically and may require additional set-up and start-up time. For
using electric heating cartridges or heating bands. The specific details about hot runner systems and processing
manifold and bushings that extend from the manifold are we recommend calling the supplier directly.
thermostatically controlled. The two most popular types of
systems that exist are:
• One with no moving parts which relies on the insulating
properties of the plastic at the gate area to keep it from
drooling, and
• A mechanical shut off type called “valve gate”
Figure 5 illustrates three generic types of hot runner gates.

Figure 5: Generic hot runner gating types

Through flow type Valve gate type Hot tip type


NOT SUGGESTED
FOR FILLED PPS

Ryton® PPS Processing Guide / 13


Appendix
Appendix A – Ryton® PPS Compound Typical Processing Data
Unit R-4-200NA, R-4-220NA R-7-120NA, BR111
Machine Data
Shot size % of capacity 50 50
2
Clamp tonnage/in 2.5 – 4 2.5 – 4
Screw type – L/D, comp. ratio 16 – 20:1, 2.5:1 16 – 20:1, 2.5:1
Check valve type Ring, abrasion resistant Ring, abrasion resistant
Nozzle type Shut-off or reverse taper Shut-off or reverse taper
Special materials, screw Stellite or Colmonoy 56 Flights
® ®
Stellite or Colmonoy ® 56 Flights
®

Barrel Xaloy ® 802 Xaloy ® 802


Temperature ranges
Nozzle ºC (ºF) 302 – 327 (580 – 620) 302 – 332 (580 – 630)
Front ºC (ºF) 316 – 343 (600 – 650) 316 – 343 (600 – 650)
Middle ºC (ºF) 302 – 327 (580 – 620) 302 – 327 (580 – 620)
Rear ºC (ºF) 293 – 316 (560 – 600) 293 – 316 (560 – 600)
Melt (typical/max) ºC (ºF) 327/343 (620/650) 332/343 (630/650)
Mold (optimum) ºC (ºF) 135 – 149 (275 – 300) 135 – 149 (275 – 300)
Pressures setting
Injection, 1st stage psi 200 – 400 > peak pressure 200 – 400 > peak pressure
Injection, 2 stage
nd
psi Max. to achieve density Max. to achieve density
Back psi 50 – 100 50 – 100
Injection fill time (typical) sec 0.5 – 2.0 1.0 – 2.0
Injection hold time (typical) sec 7 – 10 5 – 8
Screw settings
Cushion mm (inch) 2.54 – 6.35 (0.10 – 0.25) 2.54 – 6.35 (0.10 – 0.25)
RPM 100 100
Mold Data
Special materials A-2, D-2 Steel, Rc 60+ A-2, D-2 Steel, Rc 60+
Gates
Tunnel, diameter mm (inch) 1.0 – 2.5 (0.040 – 0.100) 1.0 – 2.5 (0.045 – 0.120)
Pin, point diameter mm (inch) 1.0 – 2.5 (0.040 – 0.100) 1.0 – 2.5 (0.045 – 0.120)
Edge, thickness mm (inch) 1.0 – 2.5 (0.040 – 0.100) 1.0 – 2.5 (0.045 – 0.120)
Width mm (inch) 1.5 – 5.0 (0.060 – 0.200) 1.5 – 5.0 (0.080 – 0.200)
Land mm (inch) 0.5 – 0.76 (0.020 – 0.030) 0.5 – 0.76 (0.020 – 0.030)
Vent
Thickness mm (inch) 0.008 – 0.013 (0.0003 – 0.0005) 0.008 – 0.013 (0.0003 – 0.0005)
Land mm (inch) 1.52 – 2.29 (0.060 – 0.090) 1.52 – 2.29 (0.060 – 0.090)
Minimum runner diameter
L = 127 (5) mm (inch) 3.175 (0.125) 4.775 (0.188)
L = 254 (10) mm (inch) 4.775 (0.188) 6.350 (0.250)
L = 381 (15) mm (inch) 6.350 (0.250) 7.950 (0.313)
Draft angle Degree 0.5 – 2 0.5 – 2
Undercut maximum % 0 0

14 \ Ryton® PPS Processing Guide


Unit R-4-200NA, R-4-220NA R-7-120NA, BR111
Maximum flow
Part thickness, mm (inch)
1.02 (0.040) mm (inch) 12.7 (5) 12.7 (5)
1.52 (0.060) mm (inch) 33 (13) 30.5 (12)
2.03 (0.080) mm (inch) 16 (40.6) 14 (35.6)
2.54 (0.100) mm (inch) 19 (48.3) 16 (40.6)
Thinnest allowable wall mm (inch) 0.010 (0.254) 0.015 (0.381)
Material drying time hrs 2 – 4 2 – 4
Temperature °C (°F) 135 – 149 (275 – 300) 135 – 149 (275 – 300)

Appendix B – Auxiliary Equipment


Application Engineering Corp./AEC Inc. Sterling
1100 Woodfield Rd., Suite 588 2900 S. 160th Street
Schaumburg, IL 60173 New Berlin, WI 53151
+1 847-273-7700 +1 262-641-8610
www.aecinternet.com www.sterlco.com

Conair Wittmann Inc.


One Conair Drive One Technology Park
Pittsburg, PA. 15202 Torrington, CT 06790
+1 412-312-6000 +1 860-496-9603
www.conairnet.com www.wittmann-ct.com

Appendix C – Injection Molding Ryton® PPS Trouble-Shooting Guide


In using this trouble-shooting guide, it should be kept in mind that only one change should be made at a time, and the
result determined unless it is very apparent that more than one factor is in error. In addition, the “Possible Cause” and
“Solution” should each be taken in the order listed – again, unless it is obvious which factor should be corrected.

In some cases, a composite of several causes may complicate the situation to a point where no single solution would be
satisfactory. Under these conditions, a systematic review of the molding conditions and operation would be necessary to
determine the major problem.

Problem Possible Cause Solution


Mold does not fill Shot size too small lncrease shot size, maintain a 3.2 mm (0.25 inch) cushion
minimum.
Cut-off transfer position too short Decrease cut-off transfer position.
Inadequate pressure Increase boost, pack or hold pressure.
Injection rate too low Increase injection rate and/or increase boost pressure
if pressure limited.
Material too cold Increase melt temperature.
Injection time too short Increase boost, pack or hold time.
Trapped air or gas Vent mold in unfilled area 0.0127 mm (0.0005 inch) deep.
Mold temperature too low Increase mold temperature.
Gate/runner too small Increase gate/runner/sprue size and/or decrease gate
land length.
Insufficient material in hopper Add resin to hopper.
Excessive clearance between Replace worn parts.
non-return valve and barrel

Ryton® PPS Processing Guide / 15


Part contains voids Part not packed out lncrease shot size.
Decrease cut-off transfer position.
Increase injection boost pressure.
Increase injection pack or hold pressure.
Increase injection time forward.
Increase pack or hold time.
Mold temperature too low Increase mold temperature to 135 – 149 °C (275 – 300 ºF).
Injection rate too high Decrease injection rate.
Excessive wall thickness Reduce wall thickness or core out thick sections.
Material is wet Dry compound, 135 – 163 °C (275 – 325ºF) for 2 to 3 hours.
Reduce melt temperature.
Trapped air or gas Change gate location.
Dull or mottled surface Mold too cold Increase mold temperature to 135 – 149 °C (275 – 300 º F).
Part not packed out lncrease injection boost pressure.
lncrease injection pack pressure.
lncrease injection time forward.
Increase shot size.
Decrease cut-off position.
Increase pack or hold time.
Injection rate too slow Increase injection rate.
Material too cold Increase melt temperature.
Parts develop internal cracks Molded-in stress Reduce fill rate.
Increase mold temperature.
Wall thickness too heavy for Reduce wall thickness or core out thick sections.
compound
Use compound with higher molecular weight base.
Corner radius too sharp Increase corner radius.
Parts cool too quickly Increase mold temperature.
Put parts in insulated container to cool.
Parts warp Parts cool unevenly Correct mold temperature variation.
Reduce variation in wall thickness.
Reduce mold temperature.
Increase mold closed time.
Apply a differential mold temperature to counteract
warpage.
Use a post mold cooling fixture.
Reduce melt temperature.
Parts under packed lncrease injection pack or hold pressure.
Increase injection pack or hold time.
Increase shot size.
lnjection speed too high Reduce injection speed.
Parts eject unevenly or stick Check for proper part ejection.

16 \ Ryton® PPS Processing Guide


Weld lines are weak (crack) Inadequate melt temperature Increase melt temperature.
Parts under packed lncrease injection pack or hold pressure.
Increase injection pack or hold time.
Increase shot size.
Injection rate too low Increase injection rate.
Increase injection boost pressure.
Air entrapment in cavity Improve venting in weld line area, 0.0127 mm (0.0005
inch) deep. Provide material overflow.
Gate location Move gate to place weld line in area of reduced stress or
thicker section.
Restricted flow path Increase nozzle, sprue, runner or gate size.
Light tan or black Air entrapment Reduce injection rate.
Burned area on parts
Vent cavity in problem areas by flattening ejector pin
sides, parting line vents, 0.0127 mm (0.0005 inch) deep,
or vacuum vent.
Move gate to allow better venting.
Parts do not have adequate Parts do not have adequate Increase mold temperature to 135 – 149 °C (275 – 300 ºF).
dimensional stability or stiffness after crystallinity Anneal or heat treat parts before use, 2 to 6 hours at
exposure to elevated temperature 204 to 232 °C (400 to 450 ºF).
Parts do not eject from mold cores Parts shrink onto core Check mold for undercuts. Draw polish cores and
cavities.
Reduce core temperature.
Increase injection pressure.
Increase injection time forward.
Increase injection rate.
Reduce mold closed time.
Use mold release spray
(Zinc stearate, tge silicones, etc.).
Dry blend 0.05 to 0.10 % zinc stearate into resin.
Insufficient draft on core Increase draft on core.
Parts do not eject from mold cavity Part sticks in cavity Polish out undercuts in cavity or add undercuts to core
to keep part on core.
Reduce mold temperature.
Reduce injection time forward.
Reduce injection rate.
Increase mold closed time.
Reduce stock temperature.
Insufficient draft in cavity Increase draft in cavity.
Parts difficult to eject or break on Insufficient ejector surface or ejector lncrease number of ejector pins.
ejection pins in wrong locations
Increase ejector surface area.
Add ejector pins.
Part top hot Increase cooling time.
Decrease mold temperature to 135 – 149 °C
(275 – 300 º F).

Ryton® PPS Processing Guide / 17


Sprue does not pull Undercut on sprue bushing Ream and draw polish sprue bushing.
Flash between nozzle and sprue Reface sprue bushing and nozzle, check alignment.
bushing
Insufficient shrinkage of sprue Decrease packing or hold pressure.
Insufficient taper of sprue brushing
Decrease hold or cooling time Increase taper on sprue
bushing.
No sprue puller Use “Z” sprue puller.
Nozzle drool Material wet Dry material for 2 - 4 hrs. at 135 – 163 °C (275 – 325 °F).
Nozzle tip too hot Lower nozzle temperature.
Increase decompression.
Material too hot Lower front barrel temperature.
Decrease back pressure.
Decrease mold open time.
Use a smaller orifice nozzle.
Use a reverse taper nozzle.
Use a shut off nozzle.
Nozzle freeze off Nozzle temperature too low Increase nozzle temperature.
Use a larger orifice nozzle.
Decrease the cycle time.
Mold temperature too low lncrease mold temperature.
Insulate the nozzle from the mold.
Material temperature too low lncrease barrel temperatures.
Increase back pressure.
Surface imperfections Cold slug Use a cold slug well.
Decrease nozzle temperature.
Cold mold lncrease mold temperature to 135 – 149 °C (275 – 300 ºF).
Flash Injection pressure too high Decrease cutoff position.
Decrease injection time forward.
Decrease injection pack pressure.
Material temperature too high Decrease barrel temperature.
Lower back pressure.
lnjection rate too high Decrease injection rate.
Mold temperature too high Decrease mold temperature.
Clamp force too low lncrease clamp force or evaluate moving mold to a larger
press.
Mold wear or misalignment Check the mold for cavity edge wear
Check for proper mold alignment.
Check for material caught on the parting line surface.
Tooling wear All highly filled compounds are quite lncrease stock temperature.
abrasive and tend to cause tool
wear. This wear is most severe in Decrease injection speed.
areas of highest material velocity. Use extremely hard inserts such as tungsten carbide in
these areas of the mold.
For tool steel recommendations, refer to Ryton® PPS
Design Guide.
Excessive Wear of Screws, Barrels Material not properly and adequately lncrease stock temperature.
and Check Valves melted
Decrease back pressure.
Screw, check valves or barrel Use bimetallic barrel along with hardened flights on
Material not hard enough screw. Refer to Ryton® PPS Design Guide.

18 \ Ryton® PPS Processing Guide


Ryton® PPS Processing Guide / 19
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