Quick Guide to Injection Molding
Ixef PARA
®
Equipment Table 1: Drying instructions
Ixef polyarylamide (PARA) resins can be processed on
®
Drying Method Temperature Hours
conventional injection molding equipment.
Hot air 80 °C (176 °F) 12
• Estimated clamp tonnage of 1T/cm2 (4 T/in2 ) is required. Desiccant 120 °C (248 °F) 4–5
• Standard (general purpose) screws with a compression
ratio between 2 : 1 and 3 : 1 and a L/D ratio between Drying
15 : 1 and 20 : 1 are suggested.
Ixef ® PARA compounds are delivered in granular form
• Use a ring-check valve, not a ball-check valve. (bulk density around 0.7 g/cm3 ) usually in 25-kg bags or
• Use a reverse taper nozzle to minimize drooling or 1-ton octabins. Both package types are sealed and water-
freeze off. tight, so it is not necessary to dry the product before
• Use insulation plates between the mold and machine processing. Bags opened for 24 hours or more should be
platens. dried according to the guidelines in Table 1.
• Use a mold temperature control unit with either water or
oil depending on the processing temperatures required. Injection
• When using oil heaters, ensure that lines, seals, and The settings of the injection phase cannot be carried
heat transfer fluids are suitable for the processing out until the mold temperature and material temperature
temperatures. are correct and verified above 120 °C (248 °F). An item
molded with the mold temperature being too low can
• Use a desiccated hopper dryer to ensure that the resin
suffer from the following defects:
remains dry during processing.
• Select a barrel capacity for a residence time no greater • Increased moisture pick-up
than 6 minutes. An indication of the residence time is • Risk of post-crystallization
given by:
• Poor surface appearance
Barrel Cycle Time,
Residence Time, Capacity x Seconds • Higher tendency to creep
Minutes =2x
Shot Size x 60 • Lower shrinkage
• Hot runner systems must be designed for high- See Table 2 for starting point molding conditions.
temperature crystalline polymers.
Technical Bulletin Specialty Polymers
Table 2: Starting point molding conditions Table 3: Hold and cooling
Material temperature (purged) Hold time [seconds] 3 s × w (3)
Standard grades 280 °C Cooling time [seconds] 2.5 s × w 2 (4)
(536 °F)
(1)
w = wall thickness, mm
Flame-retardant and < 270 °C (2)
w = wall thickness, mm, ≥ 2 mm
impact-modified grades (< 518 °F)
Cylinder temperatures
Feed zone 250 °C to 280 °C Troubleshooting
(482 °F to 536 °F )
Table 4 is a troubleshooting guide that contains the
Compression zone 250 °C to 280 °C solution to many common molding problems. If problems
(482 °F to 536 °F )
persist, contact your Solvay representative for additional
Metering zone 250 °C to 280 °C
assistance and technical service.
(482 °F to 536 °F )
Nozzle zone 260 °C to 290 °C
(500 °F to 554 °F) Safety Procedures
Hot runners (when used) 250 °C to 280 °C Proper safety procedures must be followed at all times:
(482 °F to 536 °F )
• All machine guards and covers must be in place.
Mold temperature 120 °C to 140 °C
(248 °F to 284 °F) Required personal protection equipment must be
Injection speed High,
worn. Face shields, gloves, and long sleeves are
0.5 s to 2.5 s recommended. Purge barriers should be placed
Hold pressure 500 bar to 1,500 bar (specific) against the sprue bushing to protect the tool. Purged
(7,250 psi to 21,750 psi) materials are very hot and should be handled and
Back pressure 0 bar to 10 bar (hydraulic) disposed of with care.
(0 psi to 150 psi) • Always be alert of the possibility that resin
Screw speed 3 m/min to 10 m/min decomposition can occur. Typical signs of resin
decomposition include badly discolored resin
purge and excessive gas generation. When resin
Temperature decomposition is suspected, assume that gas at
• Ixef ® PARA compounds require a mold high pressure is present and take appropriate action
temperature of at least 120 °C (248 °F) to prepare for the release of high-pressure gas. Be
• Verify the temperature of the mold cavities using a particularly cautious with plugged nozzles and follow
temperature probe. all established safety guidelines.
• Confirm the melt temperature using a temperature
probe moved about in a volume of melt, shot onto
an insulator (a glove, cardboard, etc.).
Shot Volume
• Set the initial cooling time.
• Set a zero hold time and/or pressure.
• Inject incomplete parts by gradually increasing the shot
volume using an average to high injection speed.
• When the mold is almost filled (95 % to 98 %), set the
initial hold pressure and gradually increase the hold
time. See Table 3 for more specific guidelines.
• In this way, the end of the filling is done under constant
pressure and part over-packing is avoided.
2 \ Quick Guide to Injection Molding Ixef® PARA
Table 4: Troubleshooting guide
Problems Suggested Remedies
Greasy spots on the parts and mold (signs of degradation) • Reduce material temperature (screw and/or hot runners)
Whitish spots (same phenomenon but with cold mold) • Increase mold temperature
• Reduce material temperature (screw and/or hot runners)
• Release agents, lubricants
Bad surface appearance • Increase mold temperature
• Increase injection speed
• Verify holding time and pressure
Glass fibers visible on surface • Increase mold temperature
• Increase injection speed
• Increase runner dimensions
• Increase material temperature
Jetting • Modify injection point position
• Reduce the initial injection speed
• Increase the cross-sectional area of the injection point
Burning • Increase venting
• Reduce injection speed at end of filling
Incomplete part • Increase shot volume
• Increase injection pressure and speed
• Increase runner dimensions
• Increase material temperature
• Increase venting
Deformed part • Increase the temperature of the mold
• Modify the part design, avoiding major thickness differences
• Increase holding pressure to reduce shrinkage
• Modify position and dimension of the injection gate
• Increase the cooling time
Part or sprue sticks in the mold • Reduce holding time
• Reduce holding pressure level
• Increase the draft angle of the mold cavity
Sink marks • Increase the holding time and pressure
• Change the position and dimension of the injection point
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