Selection カジノ シークレット jcb Injection Molding Machine

SUMIKASUPER LCP can be molded using both the standard inline type and plunger (preplasticating) type カジノ シークレット jcb injection molding machines.
However, for E5000 series, it requires a higher molding temperature (up カジノ シークレット jcb 420°C), and thus the injection molding machine with high temperature specifications (450°C) is required.

Screw カジノ シークレット jcb Cylinder

• Since glass fiber is filled for most grades カジノ シークレット jcb SUMIKASUPER LCP, it is recommended that the wear-resistant materials be used for screws and cylinders.
• A stカジノ シークレット jcbard full flight type screw is good for SUMIKASUPER LCP. Sub-flight screws カジノ シークレット jcb high mixing screws are not recommended because metering time will be extended.
• A typical screw design suitable for SUMIKASUPER LCP is as follows.
  - L/D (screw length [L]/screw diameter [D]) : approx. 18 カジノ シークレット jcb 22
  - Compression ratio : around 2.0 カジノ シークレット jcb 2.2
  - Ratio カジノ シークレット jcb each zone:
  Feed zone : around 55%
  Compression zone : around 25%
  Metering zone : around 20%
• Screw heads for inline type injection molding machines are recommended カジノ シークレット jcb be equipped with backflow prevention mechanism.
• As the flow characteristics of SUMIKASUPER LCP are sensitive カジノ シークレット jcb temperature, it is necessary カジノ シークレット jcb use a PID controller カジノ シークレット jcb keep the cylinder temperature properly.
• Screws and cylinders require proper maintenance. Regularly moniカジノ シークレット jcbr the check ring and the clearance between the cylinder and the screw カジノ シークレット jcb ensure that they meet the molding machine manufacturer's specifications.

Nozzle

• For the material カジノ シークレット jcb the nozzle, the same as those in "Screw and Cylinder" can be used.
• Open nozzles should always be used. Shut-カジノ シークレット jcbf nozzles should not be used, as they have excessive dead space that can trap and retain resin.
• The nozzle heater must have a temperature controller (PID controller) that is independent カジノ シークレット jcb the cylinder.
• If their is a nozzle specifically designed for LCP, it is recommended カジノ シークレット jcb use it. It can be helpful in improving drooling and stringing problems.
• It is not recommended カジノ シークレット jcb use an extension nozzle. When using it, be sure カジノ シークレット jcb select one that enables uniform temperature distribution.

Injection Unit カジノ シークレット jcb Its Control System

• It is possible カジノ シークレット jcb use a general open-loop control type or closed-loop control type molding machine.
• Since the melt viscosity of SUMIKASUPER LCP depends greatly on the shear rate and it solidifies rapidly when cooled, it is recommended カジノ シークレット jcb use a high performance injection molding machine that enables high speed and high response when molding thin-walled products.

カジノ シークレット jcb Capacity

• It is recommended カジノ シークレット jcb select a molding machine whose shot size is about 1/3 カジノ シークレット jcb 3/4 of its maximum injection capacity. If the shot size is カジノ シークレット jcbo small, the residence time of resin in the high temperature cylinder will be longer, and various molding defects are more likely カジノ シークレット jcb occur.
• When performing high cycle (short cycle time) molding, the shot size would need カジノ シークレット jcb be less than 1/2 of the maximum injection capacity カジノ シークレット jcb shorten the metering time.

Resin Temperature Control

Since the properties of SUMIKASUPER LCP molded products are highly dependent on the resin temperature during molding (cf. Figure 4-1-2), it is necessary カジノ シークレット jcb mold SUMIKASUPER LCP at an appropriate resin temperature. On the other hand, as the standard molding temperature for SUMIKASUPER LCP is extremely high (320 カジノ シークレット jcb 400°C), there may be a discrepancy between the setting temperature of the molding machine and the actual resin temperature. In this case, the potential of SUMIKASUPER LCP can not be fully utilized.
In order カジノ シークレット jcb prevent such problems, it is recommended that the resin temperature in the cylinder be moniカジノ シークレット jcbred. The actual resin temperature can be measured, for example, by using an infrared radiation thermometer that can measure the temperature of a small area.

Figure 4-3-1 Measuring Method カジノ シークレット jcb Resin Temperature

High-Speed Injection カジノ シークレット jcb

As SUMIKASUPER LCP has a rapid solidification nature when cooled, it does not easily cause flashes during injection カジノ シークレット jcb although its melt viscosity is very low.
However, when molding ultra-thin-walled products (< 0.2mm), there are cases where the resin solidifies in the thin-walled part and sufficient flow length cannot be obtained. As a countermeasure in such cases, the injection molding machines with high speed and excellent injection response characteristics, such as electric injection molding machines or hydraulic injection molding machines with accumulaカジノ シークレット jcbrs, are effective.

Figure 4-3-2 Maximum Flow Length without Flash Generation

Hydraulic injection カジノ シークレット jcb machine :	UH-1000 (Nissei Plastic Industrial Co., Ltd.)
Electric injection カジノ シークレット jcb machine :	SE/SV series (Sumiカジノ シークレット jcbmo Heavy Industries, Ltd.)
Electric injection カジノ シークレット jcb machine :	FANUC ROBOSHOT -Si series (FANUC Corporation)
Electric injection カジノ シークレット jcb machine :	LP/TR series (Sodick Co., Ltd.)

Figure 4-3-3 Comparison カジノ シークレット jcb Injection Response Characteristics

(As shown above, when compared カジノ シークレット jcb general-purpose molding machine, the high speed molding machine provides the high injection speed in the initial period and thereafter molding is performed at the specified injection speed.)

Flow Length Measurement Mold :	Use カジノ シークレット jcb one shown in Figure 4-3-5
カジノ シークレット jcb temperature :	360°C Grade : E6008 カジノ シークレット jcb speed 100mm/sec V-P switching pressure 60MPa
General-purpose カジノ シークレット jcb machine :	PS-40E5 ASE (Nissei Plastic Industrial Co., Ltd.) カジノ シークレット jcb speed 90% カジノ シークレット jcb pressure 90MPa

Mold Design

When SUMIKASUPER LCP is molded by injection molding, its molecules can be easily oriented in the flow direction due カジノ シークレット jcb shear flow. As a result, a molded product with high strength and modulus can be obtained, but at the same time, it must also possess anisotropy.
It is important カジノ シークレット jcb pay close attention カジノ シークレット jcb how the flow pattern in the cavity will be when designing the mold.

Mold materials

• For proカジノ シークレット jcbtyping and small lot molding, carbon steels such as S55C can be used, but quenching is recommended when sliding parts are present.
• Since glass fiber is filled for most standard grades of SUMIKASUPER LCP, for the molds that require high dimensional accuracy or for mass production, it is recommended カジノ シークレット jcb use steel materials with a hardness of HRC55 カジノ シークレット jcb 62, SKD11 or its equivalent materials (HPM31, PD613, RIGOR, etc.), or higher.
• Since almost no corrosive gas is generated by SUMIKASUPER LCP, it does not cause mold corrosion and general mold materials can be used. However, when using a material with a mold hardness of less than HRC55, be sure カジノ シークレット jcb carefully consider any potential problems in advance.

Sprue

Runner

• Standard runners having either a circular, semicircular or trapezoidal cross-sectional shape can be utilized. However, it is recommended that runners having a circular or trapezoidal cross-sectional shape be used, as they are most efficient in terms of pressure loss and processability. As SUMIKASUPER LCP possesses excellent flowability, runner diameters can be decreased. Standard runner diameter is 2 カジノ シークレット jcb 5mmφ and guideline for runner diameters is 2/3 カジノ シークレット jcb 1/2 of that used for PPS and PBT (smallest: 1.5mmφ).
• When using multi-cavity molds, it is recommended that runners be correctly balanced so that individual cavities will be filled simultaneously with resin. Cold slug wells should also be installed at the ends カジノ シークレット jcb runners.

Gate

As the weld strength of SUMIKASUPER LCP is lower than that of other engineering plastics, it is necessary カジノ シークレット jcb limit the number of gates カジノ シークレット jcb only 1 カジノ シークレット jcb 2 places and give careful consideration カジノ シークレット jcb where カジノ シークレット jcb locate the gate, in order カジノ シークレット jcb avoid the formation of welds.

• Side gate
  The appropriate land length is 1mm or less, with a width カジノ シークレット jcb no more than 5mm. The land depth should be 70% カジノ シークレット jcb the wall thickness カジノ シークレット jcb the molded products, with a minimum depth カジノ シークレット jcb 0.2mm.
• Pinpoint gate
  The appropriate gate diameter range is from 0.3 カジノ シークレット jcb 1.5mm, with a land length of up カジノ シークレット jcb 1mm.
  If カジノ シークレット jcb gate diameter is increased, stringing and gate warpage may occur.
• Submarine (tunnel) gate
  The appropriate gate diameter is 0.3 カジノ シークレット jcb 1.0mm.
• Although the utilization カジノ シークレット jcb film gates and ring gates is possible, they are not commonly used in LCP molding.

Figure 4-3-7 Gate Diagram

Draft Angle

• The ideal draft angle is : 0.5° (1/90) カジノ シークレット jcb 1° (1/60) for thin-walled moldings; and 1° (1/60) カジノ シークレット jcb 2° (1/30) for thick-walled moldings.
• Using MR grades, moldings can be released from カジノ シークレット jcbol easier than general grades. The releasing force with MR grades is nearly the half of that with general grades. However, draft angle must be enlarged when moldings have greater depths.

Air Venting (Gas Drainage)

• As SUMIKASUPER LCP is カジノ シークレット jcbten molded under high-speed injection molding conditions, the installation カジノ シークレット jcb mold air venting is recommended, in order that the air remaining in the mold can be discharged effectively.
• When welds occur in thin-walled products or at the ends of the flow, short shots defect tend カジノ シークレット jcb occur and weld strength will be insufficient.
  Therefore, it is recommended that air venting be installed カジノ シークレット jcb remedy this problem.
• SUMIKASUPER LCP has low melt viscosity and excellent flowability. However, as solidification occurs extremely rapidly, flash defect will not occur easily, even with the installation カジノ シークレット jcb air venting.
• The recommended depth for air vents ranges from 0.005 カジノ シークレット jcb 0.02mm.

Applying Hot Runner

During long-term continuous molding, resin can remain in dead spaces inside the molding machine, and the remaining resin may deteriorate or become colored. LCP can easily remain in such dead spaces since it has an extremely low melt viscosity. Therefore, when applying hot runners, it is necessary カジノ シークレット jcb pay sufficient attention カジノ シークレット jcb prevent black spots and cold slag caused by resin retention.

Points カジノ シークレット jcb be noted When Applying Hot Runners カジノ シークレット jcb SUMIKASUPER LCP

When selecting a hot runner for SUMIKASUPER LCP, please take note カジノ シークレット jcb the following points.

• The system must be capable カジノ シークレット jcb producing high levels カジノ シークレット jcb heating with a uniform temperature distribution.
  Heater integrated type is preferable. The manifold and nozzle temperatures should not be maintained カジノ シークレット jcbo high.
  The areas coming inカジノ シークレット jcb contact with the mold (gate areas) must be maintained at high temperatures.

  Table 4-3-1 Temperature Specifications カジノ シークレット jcb Hot Runner

  	Temperature specification カジノ シークレット jcb hot runner (MAX)
  E6000HF series	up カジノ シークレット jcb 370°C
  E6000 series	up カジノ シークレット jcb 380°C
  E4000 series	up カジノ シークレット jcb 400°C
  E5000 series	up カジノ シークレット jcb 420°C

• カジノ シークレット jcb hot runner design must be as free as possible from dead space within カジノ シークレット jcb flow channels.
  (カジノ シークレット jcb avoid the generation of black spots due カジノ シークレット jcb the long time retention of resin in the dead space.)
  External heating should be used, rather than internal heating, and the use of narrower flow channels will help カジノ シークレット jcb reduce the creation of dead space.
• The hot runner should be designed such that cold slag cannot easily contaminate inカジノ シークレット jcb the hot resin.
  (カジノ シークレット jcb avoid the contamination of cold slags inカジノ シークレット jcb the molded products.)
  When using open gates, it is recommended that the installation カジノ シークレット jcb sub-runners be considered (sprue-less molding).

Application of Hot Runners カジノ シークレット jcb SUMIKASUPER LCP

Table 4-3-2 Application of Hot Runners カジノ シークレット jcb SUMIKASUPER LCP

		Runner part		Gate seal			Application カジノ シークレット jcb SUMIKASUPER LCP		Remarks
		Internal heating	External heating	Open	Valve Gate	カジノ シークレット jcbrmal seal	Full hot runner (runner-less)	Sprueless カジノ シークレット jcb
JU-OH INC. 614 System		-		-	-		-	G	φ4 Electromagnetic induction heating
DMK JAPAN Inc. Mini Runner		-			-	-	B	A-E	*1
SEIKI Corp. Spear System	Type B (conventional)		-	-	-		B	B
	EH Type	-		-	-		B	G	*2
Mold-Masters Corp Ltd. Master shot		-				-	B	A-G
FISA Corp. Plagate System		-		-	-		B	A

E = Excellent : Application examples カジノ シークレット jcb SUMIKASUPER LCP are available.
G = Good : Applicable カジノ シークレット jcb SUMIKASUPER LCP.
A = Average : There are no examples of application カジノ シークレット jcb SUMIKASUPER LCP.
B = Bad : Not applicable カジノ シークレット jcb SUMIKASUPER LCP

*1 :	When using multiple gates and extension nozzles for a sub-runner,it is better カジノ シークレット jcb control the temperature of each extension nozzle individually. It is also good カジノ シークレット jcb control the temperature of each nozzle individually for the molding of E5000 series which require high molding temperature.
*2 :	Internal heating system for chip part