Ryton PPS Processing Guide en v2.1 0
Ryton PPS Processing Guide en v2.1 0
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® 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.
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)]
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)
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).
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.
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
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.
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