Molding Guide

Rynite PET

thermoplastic polyester resin

Start with DuPont

Table of Contents
Chapter 1
Page General Information ........................................... 2 Compositions ....................................................... 2 Melt Properties of Rynite PET ........................... 4 Heat Requirements for Processing .................... 4

Chapter 4

Chapter 2
Molding Equipment ........................................... 5 Barrel .................................................................... 5 Vented Barrel ....................................................... 5 Screw .................................................................... 5 Screw Check Ring Assembly .............................. 6 Screw Tip .......................................................... 6 Check Valves .................................................... 6 Nozzle ................................................................... 6 Machine Controls ................................................ 6

Page Molding Conditions ......................................... 13 Cylinder and Melt Temperatures ..................... 13 Nozzle Temperature .......................................... 13 Mold Temperature ............................................ 13 Injection Pressure/Flow ..................................... 14 Fill Rate ............................................................... 14 Screw Speed/Back Pressure ............................. 14 Purging ............................................................... 14 Start-up .............................................................. 15 Shutdown ........................................................... 15

Chapter 5
Mold Design ...................................................... 17 Sprues and Runners .......................................... 17 Gates .................................................................. 17 Vents ................................................................... 17 Undercuts and Taper ........................................ 17 Wear ................................................................... 17 Tolerances .......................................................... 18

Chapter 3
Drying Guidelines ............................................... 7 Effects of Moisture .............................................. 7 Dehumidified Hopper Dryer Conditions ............ 8 Dehumidified Hopper Dryer Equipment ............ 8 New Systems ................................................... 8 Retrofit of Existing Systems ......................... 10 Dryer Maintenance ............................................ 10 Filters .............................................................. 10 Desiccant Beds ............................................... 10 Desiccant Bed Transfer System and Air Circuits ........................................... 11 Blowers, Heaters, Thermocouples, Amperage ................................................... 11 After-cooler and Volatiles Trap ..................... 11 Dew Point Temperature and Air Flow Monitors ............................... 11 Partial List of Dew Point Meter Suppliers .......................................... 11 Desiccant Suppliers ....................................... 11 Drying System Troubleshooting Guide ........... 12

Chapter 6
Other Considerations ....................................... 19 Rework ............................................................... 19 Lubricants .......................................................... 19 Warpage ............................................................. 19 Mold Shrinkage ................................................. 20 Summary of Variables Affecting Toughness and Strength ........... 21 Safety Precautions ............................................ 21

Chapter 7
Troubleshooting Guide .................................... 23 Model of Molding Data Record Sheet ............. 24

Chapter 1 General Information

Compositions
Rynite PET glass-reinforced thermoplastic polyester resins contain uniformly dispersed glass or glass/mineral fibers in polyethylene terephthalate (PET), specially formulated for rapid crystallization during the injection molding process. This makes possible the production of high performance parts by conventional injection molding techniques. Rynite PET resins are available in a variety of compositions. A description of these compositions follows. Recommended molding conditions are covered in Chapter 4.

General Purpose Grades

Table 1 Compositions
Standard Compositions General-Purpose Grades Rynite PET 520 20% glass-reinforced modified polyethylene terephthalategood balance of strength, stiffness, specific gravity, and toughness with good surface appearance. 30% glass-reinforced modified polyethylene terephthalateoutstanding balance of strength, stiffness, and toughness, excellent electrical properties, surface appearance, and chemical resistance. Housings, electrical components, covers, frames, bobbins.

Characteristics

Candidate Uses

Rynite PET 530

Electrical/electronic parts such as ignition components, relay bases, lamp sockets, bobbins; housings and other parts for pumps; mechanical components including gears, sprockets, vacuum cleaner parts, motor end bells; chair arms, casters, and other furniture parts. Lamp housings, compressor housings, fuel, air, and temperature sensor housings, sunroof frames, spools, bobbins, transmission components, medical devices. Structural support brackets, housings and covers, auto parts, bicycle components, propellors.

Rynite PET 545

45% glass-reinforced modified polyethylene terephthalategreater strength and stiffness, excellent dimensional stability, and creep resistance. 55% glass-reinforced modified polyethylene terephthalatesuperior stiffness, dimensional stability, heat resistance, and outstanding resistance to creep.

Rynite PET 555

Low Warp Grades Rynite PET 935 35% mica/glass-reinforced modified polyethylene terephthalateexceptionally low warpage, excellent electrical properties, high stiffness, and high heat resistance. 40% mica/glass-reinforced modified polyethylene terephthalategreater strength, stiffness, and low warpage. Exterior body parts, structural housings and frames, irrigation components, electrical components including transformer and ignition coil housings. Frames, exterior body parts; structural supports.

Rynite PET 940

(continued)

Table 1 Compositions (continued)

Standard Compositions Toughened Grades Rynite PET 408 30% glass-reinforced modified polyethylene terephthalate with improved impact resistance. Excellent balance of strength, stiffness, toughness, and temperature resistance. 15% glass-reinforced modified polyethylene terephthalateimproved for easy, fast processing over a broad molding rangeexcellent balance of strength, stiffness, and temperature resistance. 35% stiffened, super-tough, glass-reinforced modified polyethylene terephthalatesuperior combination of toughness and stiffness. Excellent surface appearance, moldability, and temperature resistance. Water pump housings, structural housings and brackets, electrical and electronic housings, luggage rack components. Snap fit applications, encapsulation of sensors, coils, etc. Characteristics Candidate Uses

Rynite PET 415HP

Rynite PET SST 35

Automotive parts, wheels, yard and shop tools, sporting goods, luggage components, appliance housings, structural furniture components.

Flame-Retardant Grades* Rynite PET FR330 Flame-retardant, 30% glass-reinforced modified polyethylene terephthalate. Recognized by UL as 94 V-0 at 0.032. Has a 140C (284F) temperature index. Excellent balance of electrical and mechanical properties. High temperature resistance and flow. Flame-retardant, 15% glass-reinforced modified polyethylene terephthalate. Recognized by UL as 94 V-0 at 0.034. Has a 140C (284F) temperature index. Excellent balance of electrical and mechanical properties. High temperature resistance and flow. Flame-retardant, 30% glass-reinforced modified polyethylene terephthalate. Recognized by UL as 94 V-0 at 0.014. Has a 150C (302F) temperature index. Outstanding balance of properties and excellent flow characteristics. Flame-retardant, 43% glass-reinforced polyethylene terephthalate. Has a 155C (311F) temperature indexequivalent to many thermosets. Recognized by UL as 94 V-0 at 0.032. Flame-retardant, 43% glass-reinforced modified polyethylene terephthalate. Recognized by UL as 94 V-0 at 0.014. Has a 155C (311F) temperature index. Excellent balance of electrical and mechanical properties. Low warp characteristics. Flame-retardant, 45% mineral/glass-reinforced modified polyethylene terephthalate. Recognized by UL as 94 V-0 at 0.032. Has a 150C (302F) temperature index. Low warpage, high stiffness, and economical price. Flame-retardant, 46% glass-reinforced modified polyethylene terephthalate. Recognized by UL as 94 V-0 at 0.032. Has a 150C (302F) temperature index. Excellent balance of stiffness, strength, toughness, good surface appearance, and electrical properties. Electrical and electronic connectors and components such as relays, switches, lamp sockets, and fans. Used in structural components such as office equipment, fans, fan housings, and oven handles. Electrical and electronic connectors and components such as relays, switches, lamp sockets, and fans.

Rynite PET FR515

Rynite PET FR530

Electrical and electronic connectors and other components requiring flame-retardant characteristics. Used in applications employing vapor phase and wave soldering techniques. Electrical/electronic applications such as relays, switches, lighting ballasts, and terminal blocks. Electrical and electronic connectors and other components requiring low warp characteristics. Used in electronic applications such as connector bodies and terminal blocks. Electrical and electronic components. Economical for large parts requiring flameretardant characteristics, such as motor housings, bobbins, terminal blocks, and fans. Electrical and electronic components. Economical for large parts requiring flameretardant characteristics, such as connector bodies, bobbins, and terminal blocks.

Rynite PET FR543

Rynite PET FR943

Rynite PET FR945

Rynite PET FR946

*This numerical flame spread rating is not intended to reflect hazards presented by this or any other material under actual fire conditions.

Melt Properties of Rynite PET

Rynite PET thermoplastic polyester resins have excellent melt flow characteristics. The melt viscosity and, hence, melt flow, varies depending on the type and level of reinforcement and other composition factors. The melt viscosities of various compositions of Rynite PET versus temperature and comparisons to several other thermoplastic resins are shown in Figure 1.

Figure 1. Melt Viscosities of Rynite PET

1,000 9 8 7 6 5 4 At a Shear Rate of 1,000 sec1

Delrin 100 Zytel 42

Melt Viscosity, pascal seconds

3
Delrin 500

Hytrel 5556 Rynite PET 935

Heat Requirements for Processing

The polyester base resin for Rynite PET is a crystalline polymer which requires a greater heat input for melting than amorphous polymers do. This additional heat is required to break up the ordered crystalline structure of the solid polymer, and it is called the heat of fusion. The total heat required for processing Rynite PET is similar to that of glass-reinforced PBT polyester and glassreinforced nylon resins.

100 9 8 7 6 5 4 3 2

Alathon 7240

Zytel 101

Rynite PET 545/530 Zytel 70G33

Rynite PET FR 530

10

178 (350)

204 232 260 288 (400) (450) (500) (550) Melt Temperature, C (F)

316 (600)

Chapter 2 Molding Equipment

Rynite PET glass-reinforced polyester resins can be molded in all standard screw injection molding machines. General-purpose screws should be used to reduce fiber breakage. Rynite PET resins, like other glass-reinforced resins, often cause wear in certain areas of the barrel, screw and mold. Equipment and materials of construction are recommended below.

Vented Barrel
The use of vented barrels is not recommended for processing Rynite PET. Dehumidified hopper dryers should be used to remove moisture to achieve desired processing and property characteristics.

Screw
General
The general-purpose gradual compression screws that are installed (OEM) in molding machines are usually suitable for molding glass-reinforced polyester resins. At high output rates, specific screw designs will provide better uniformity of melt temperature and freedom from unmelt. Screw length should be at least an 18 to 1 (length to diameter) ratio for uniform melt temperatures at high outputs. (see Figure 2.)

Barrel
General
Three-zone heating control of the barrel (corresponding to the screws three functional zones) should be provided for close temperature control and high output rates. In all cases, the temperature of the nozzle should be independently and precisely controlled.

Wear
Bimetallic liners, e.g., Xaloy 800 or equivalent have shown outstanding resistance to wear.
Figure 2.

Suggested General-Purpose Screw* Design Rynite PET Glass-Reinforced Polyester Resins

Length Feed Section 10 Transition Section 5 Metering Section 5

DS

hF

Land Width

hM

Screw Diameter (DS) mm (in) 38.1 50.8 63.5 88.9 114.3 (1.5) (2.0) (2.5) (3.5) (4.5)

Feed Depth (hF) mm (in) 7.62 8.13 9.65 11.18 12.7 (0.300) (0.320) (0.380) (0.440) (0.500)

Metering Depth (hM) mm (in) 2.17 2.67 3.05 3.56 3.81 (0.085) (0.105) (0.120) (0.140) (0.150)

General practice in the industry is to have the land width e = 1/10 the distance between the flight, and the radial clearance = 1/1000 the diameter of the screw. *20L/D; square pitch; 10/5/5 turns for feed, transition, and metering zones, respectively.

Wear
Abrasive wear of injection screws occurs primarily on the lands and edges of the screw flights. In time, the root will wear in the transition and metering zones. Use heat treated and stress relieved alloy steel with a hard surface. An abrasion resistant coating, e.g., Colmonoy 56, e.g., UCAR WT-1, is necessary. Nitriding is not recommended. Coating solely the tips of the flights will not be adequate.

Screw Check Ring Assembly Screw Tip

Wear
The recommended material of construction is a stress relieved AISI 4140 steel, hardened to Rc52 with an abrasion resistant surface coat, e.g., Borafuse. This treatment will lead to an appreciably harder surface than that of the check ring.

appreciable wear when used with glass-reinforced resins. Even when properly hard surfaced, these valves should be considered expendable after 3 to 4 months of use. Prior to that, worn seats and ring sleeves should be reground or replaced since it is important to maintain a pad (cushion) during injection of melt. Nitriding has been found useful for extending the life of check rings. A typical material of construction is Nitralloy 135M. The seat is usually hardened more than the sleeve; e.g., seat Rc55; sleeve Rc45 are typical. Experience has shown that when the nonreturn valve fails to function correctly, additional screw wear occurs, and as the performance (wear) of the check valve deteriorates, so does the condition of the screw.

Nozzle
Heated, reverse tapered nozzles (Figure 3) are recommended for use in molding Rynite PET resins. Straight-through nozzles have been used successfully as Rynite PET resins have less tendency to drool than do glass-reinforced nylons. Positive shut-off nozzles can only be used when proper temperature control is provided, but should not be used for flame retardant grades.

Check Valves
General
Hardened check (nonreturn) valves should be used for processing Rynite PET resins. Either ring check or ball check valves may be used. With the latter, flow passages must be carefully streamlined to prevent holdup. Check valves are necessary during injection to ensure constant cavity pressure and part weight uniformity from shot to shot.

Machine Controls
No special equipment features are required to process Rynite PET resins. Using either electrical or hydraulic screw drive, these materials can be run in both toggle and hydraulic clamp machines. Clamp pressure of 35 tons/in2 (4070 MPa) of projected shot area is desirable when molding Rynite PET.

Wear
Sliding type ring check valves (nonreturn valves), especially when not hardened, undergo rapid and

Figure 3. Nozzle (with reverse taper) Recommended for Molding

0.25 cm (0.10") Radius

,,,,,,,, ,,,,,,,, ,,,,,,,,

Thermocouple Well 4 D Taper to Suit 1/8" (0.32 cm) 3D 10D

Diameter to Suit

D Minimum = 0.32 cm (1/8"), D Typical = 0.48 cm (3/16") 0.64 cm (1/4")

Not To Scale

Chapter 3 Drying Guidelines

Molded parts of Rynite PET provide an outstanding combination of high flexural modulus, strength and toughness, dimensional stability and good surface appearance. However, these properties will not be achieved in finished molded parts unless the material has been properly processed with particular attention given to thorough drying of the resin. While the required drying can be accomplished in some conventional drying equipment, the continuous manufacture of high quality production parts is assured when careful attention is given to equipment selection, dryer operating conditions and maintenance procedures. This can result in overpacking, parts and runner sticking, and flash. Parts molded from wet resin do not exhibit surface defects such as splay seen with nylon resins. Therefore, parts could be molded with excellent surface appearance and yet have poor end-use performance. As with any degraded resin, the lower properties cannot be restored by further processing. Such regrind should be discarded. Virgin resin is shipped in special moisture-proof bags or boxes at a moisture level up to 0.04%. Therefore, both virgin and regrind resins must be dried to and maintained at less than 0.02% moisture during molding. Figure 5 depicts the moisture pick-up rate of Rynite PET which is typical of polyester resins. At exposure levels of 50% R.H. or more, resin dried as low as 0.01 % moisture will likely exceed the 0.02% level after 15 min. For this reason, the use of remote tray oven dryers with manual transfer to the hopper is not recommended. Since the reaction of moisture with Rynite PET melt is quite rapid, the use of vented barrels in place of dryers is also not recommended. Therefore, dehumidified hopper dryer systems are necessary for successful drying of Rynite PET below 0.02% moisture content and maintaining the resin below this moisture level.
Figure 5. Moisture Pick-up of Rynite PET 530

Effects of Moisture
Like many other engineering thermoplastics such as nylons, polycarbonates, polysulfones and other polyesters, Rynite PET is hygroscopic (absorbs moisture from the atmosphere). When excess moisture is present in the polymer melt in an injection molding machine, a hydrolysis reaction occurs. This reaction degrades the material causing lower part toughness and strength and increased melt flow. Figure 4 illustrates the significant loss of physical properties of Rynite PET at moisture levels above 0.02% moisture. In addition, the melt flow increases rapidly as resin picks up moisture.
Figure 4. Effects of Feed Moisture on Properties of Rynite PET 530

100 90

0.1 0.08
Tensile Strength Elongation

100% RH

50% RH

% of Ultimate

% Moisture

80 70 60 50 .01 .02 .03 .04 % Moisture .05

.06 .04 .03 .02 .01 15 min 1hr 1day

15% RH

Unnotched Izod Impact

1week

Dehumidified Hopper Dryer Conditions

Properly operating dehumidified hopper dryers can dry Rynite PET resin adequately in a short period of time. The air flow rate is very important. For each pound per hour of resin processed, 0.81.0 cubic foot per min (CFM) of air is required. For example, if 60 lb/hr (27 kg/hr) of Rynite PET are to be molded, dry air capacity of 4860 CFM (82102 m3/hr) will be needed. Depending upon dryer design, lower rates will significantly reduce the resin temperature in the hopper. The air temperature is equally important. lt should be measured at the point of entry to the hopper (not at the dryer). Figure 6 illustrates the required drying times for virgin resin and wet resin. Normally, a 121C (250F) to 135C (275F) temperature is recommended with drying times ranging from 23 hr (for virgin resin from sealed packages) to 46 hr (for exposed wet resin). If the Rynite PET resins are dried overnight (e.g., 816 hr), the drying temperature should be reduced to 107C (225F). Similarly if production rates result in the hopper residence time exceeding 8 hr, the temperature should be reduced to 107C (225F). Over-weekend drying may be accomplished at 93C (200F). Prolonged drying at 121C (250F) (or higher temperatures) is not recommended and may result in volatizing a small amount of additives from the Rynite PET resin.
Figure 6. Residence Time vs. Air Temperature at 18C (0F) Dew Point to Obtain 0.02% Moisture

The third important variable is the dew point* of the air entering the hopper This must be 18C (0F) or lower throughout the drying cycle in order to adequately dry Rynite PET resins. All three of these key variablesair flow, air temperature, and air dew pointshould be monitored. Table 1 summarizes the required conditions for drying Rynite PET resins. More specific data can be obtained from your DuPont Representative. If these conditions are not being maintained by the dryer, consult the Troubleshooting Guide at the end of this chapter.
Table 1 Drying Conditions for Rynite PET
Inlet Hopper Air Temperature Dew Point of Air Airflow Rate 121C (250F) to 135C (275F) 18C (0F) or lower 0.81.0 CFM per lb/hr resin processed (3.03.7m3 per kg/hr resin processed) 66C (150F) or lower 121C (250F) 3 4 6 9 135C (275F) 2 3 4 6

Inlet Desiccant Bed Air Temperature Drying Time at:

107C (225F) Virgin Resin 8 Recycled Regrind 8 Wet Resin 8 Maximum 16

Dehumidified Hopper Dryer Equipment

The key elements to successful drying of Rynite PET and all hygroscopic materials are the proper selection of drying equipment and proper maintenance of the system (discussed later). A proper drying system is depicted in Figure 6. The numbers in parentheses below refer to the same numbered items in Figure 7.

16 14

Residence time, hr

12 10 8 6
Maximum

New Systems
Since Rynite PET resins absorb moisture quickly, automatic hopper loaders (1) are strongly recommended. If regrind is to be used, a proportionating feeder should be used. For optimum drying efficiency, the hopper dryer must be kept full. Low levels will result in decreased residence time, and some resin may not be dried adequately.
*Dew Point is the temperature to which the air must be cooled before the water vapor will condense. The more moisture there is in the air, the higher the dew point. This value can be obtained by measuring dry and wet bulb temperatures and using a psychometric chart. Hygrometer instruments giving a direct reading are more commonly used.

4 2
Wet Resin Resin As Received

104 110 116 121 127 132 138 C (220) (230) (240) (250) (260) (270) (280) (F) Hopper Inlet Temperature at 18C (0F) Dew Point

Figure 7.

Recommended Dehumidified Hopper Dryer System

2 Blower Filter Hopper Regeneration Heater

From Atmosphere

Automatic Feeder 1

Air Flow Meter C

9 Process Heater

B Dew Point Meter and Alarm 8 8 Desiccant Beds Filter 6 3 After-cooler 4 Insulation

To Atmosphere
Volatiles Trap 7 Filter A Hopper Inlet Temperature Monitor

Blower

Since an air temperature of at least 121C (250F) at the hopper inlet is normally required, a high temperature dryer is recommended. The dryer should be located as close as possible to the machine hopper and the air transfer line (2) to the hopper should be insulated. As much as 6C (10F) can be lost per foot to an uninsulated transfer line. Most dryer manufacturers provide these insulated features with high temperature dryers. For a retrofit, the equivalent of 2538 mm (1112") glass fiber insulation should be adequate. The temperature at the hopper inlet (A) should be measured by thermocouple or thermometer. In addition, the hopper itself (3) should be insulated. If the system is not insulated, the time required to dry will be increased. Once the air leaves the hopper, it requires cooling before entering the desiccant beds. Figure 8 shows that molecular sieve desiccant beds are capable of removing twice the amount of moisture at 54C (130F) versus 93C (200F) return air temperature. Since inlet air drying temperatures up to 121C (250F) are recommended, the use of an aftercooler (4) on the return air line is required. An after-cooler is simply a small heat exchanger using water cooling coils or jackets to lower the air temperature. This can be purchased with a trap (5)

Figure 8.

Maximum Desiccant Bed Moisutre Loading

18C (0F) Inlet Air Dew Point

21 20 18 16 14 12 10 8 6 4 2 0 38 (100)

Residence time, hr

149 204 93 (200) (300) (400) Temperature

C (F)

at the bottom to collect any volatiles which may condense. Another benefit is after-coolers can be equipped with a filter (6) that gives further safeguard in removal of entrained resin fines before reaching the desiccant beds.

The cooled return air passes through a filter (7) which must be made of adequate size to remove fines or any contaminant that could poison the desiccant beds (8). Filters must be checked and cleaned regularly. See Dryer Maintenance Section. Exiting the desiccant beds, the dew point (B) of the dried air should be measured continuously. Most dryer manufacturers offer dew point warning systems which indicate by a green light when the dew point is below a set point and by a red light when the set point is exceeded. This could also be converted to actuate an audible alarm. Other systems giving a continuous readout of actual dew point are also available. These are more expensive but more useful in process control and troubleshooting. It is also recommended that an air flow meter (C) be installed at this point. This can indicate when process air filter plugging is occurring and is a good supplement to the dew point alarm and hopper inlet temperature control. A filter alarm system that alerts to plugged filters is also available.

Dryer Maintenance
Equally important to successful drying of Rynite PET is a simple but good preventive maintenance program. The key dryer elements (particularly the filters) should be checked frequently. Dew point, hopper inlet temperature and airflow should be continuously monitored. Whenever these are not at desired levels, other elements require investigation over and beyond routine maintenance. They include process and regeneration heating elements, desiccant beds and bed transfer system, O-rings, gaskets and hoses, blowers, thermocouples, voltages and the meters themselves.

Filters
The primary cause of dryer failure is contamination of desiccant beds with fines, dirt, or dust due to poor filter maintenance. Even when filters are operating properly, they, in turn, will plug up and reduce airflow to unacceptable levels. Filters must be kept clean and undamaged. For sock type filters, a good practice is to replace with a spare and clean the filter at leisure. All three filters (before aftercooler, desiccant bed, and regeneration heater) should be checked once a shift to determine necessary cleaning/replacement frequency. This typically ranges from twice a week to once every two weeks. Most dryers should be turned off before inspecting the filters.

Retrofit of Existing Systems

To convert existing hopper dryer systems to achieve proper drying, the following is required: automatic resin feeder, insulation (e.g., glass fiber wrap) of hopper and its inlet air line, after-cooler with filter and volatiles trap, adequate area filter on dryer, continuous dew point, temperature and air flow measurement. Table 2 is a checklist for necessary drying equipment. All but one of these items are readily available for retrofit of existing dryer installations. The exception is if a high temperature dryer is required. The heater element and power system would need to be rebuilt.

Desiccant Beds
Figure 9 illustrates that most of the water is absorbed in the initial contact with the desiccant and very little toward the end (Curve A). As the molecular sieve repeatedly goes through the saturation/regeneration cycle, it loses some of its capacity to absorb water (Curve B). This is due, in part, to a slight loss of crystallinity which somewhat reduces efficiency. But, to a much larger degree, this can come about by coking, which is a continuous buildup of residue resulting from degrading of any foreign materials in the bed during the regeneration cycle. As a result, the desiccant has less initial capacity and requires a longer length of bed to achieve the desired dew point of existing air. Eventually the desiccant bed life is exhausted and it must be changedusually within two years (Curve C). If contamination by plastic fines occurs, regeneration temperatures will melt them and form a seal in and around the pores of the molecular sieve. The result can be an early loss of bed life.

Table 2 Dryer Equipment Checklist

Automatic Hopper Loader High Temperature Dryer Insulation of Inlet Air LIne Insulation of Hopper After-cooler/Volatiles Trap Temperature Monitor at Hopper Inlet Continuous Dew Point Analyzer Airflow Meter

10

Figure 9. Service Life of Molecular Sieve

After-cooler and Volatiles Trap

Air To Hopper

Air From Hopper Thickness of Desiccant Bed

The cooling in the chambers will necessarily trap additives and lubricants which will collect at the bottom. They should be checked periodically and any residue removed.

Dew Point Temperature and Airflow Monitors

The dew point meters should be checked and calibrated. Meters for continuous use and portable ones for calibration are available from dryer manufacturers and from suppliers listed below. Temperature monitors are easily calibrated and should be. Airflow meters should also be maintained in good working order. False low pressure readings are usually the result of pitot tubes plugged with contamination. Airflow meters can also be purchased from dryer manufacturers. Unless specified differently above, all maintenance items should be checked at least once every two months.

20 A New Dessiccant
% Moisture Absorbed in Desiccant Bed

15

B
Dew Point of Air to Hopper

10 5 0

C
Aged Desiccant

C (F) 16 (60) 4 (40) 7 (20) 18 (0) 29 (20) 40 (40)

Thickness of Desiccant Bed

Note: The values for % moisture absorbed and dew point are arbitrary but typical. Actual values would depend on design of the dryer and other operating conditions. Source: Union Carbide Corporation, Linde Division

Replacement of desiccant in cartridges is relatively easy for new dryers but older models may require a skilled maintenance man. With any dryer, refer to the manufacturers owners manual for the proper procedures. All safety precautions called for by the manufacturer should be followed. When replacing desiccant, the cartridge must be packed tightly by vibrating the cartridge as it is filled. Any void areas would allow the wet air to bypass the desiccant, since they are the paths of least resistance.

Partial List of Dew Point Meter Suppliers

Panametrics 221 Crescent Street Waltham, MA 02154 (617) 899-2719 Alnor Instrument Company 7301 N. Caldwell Avenue Niles, IL 60648 (312) 647-7866 Union Carbide Corporation Molecular Science Department Moorestown, NJ 08057 (609) 778-6283 Newport Scientific, Inc. 8246-E Sandy Court Jessup, MD 20794-0189 (301) 498-6700

Desiccant Bed Transfer System and Air Circuits

Whether the transfer mechanism is by valves or by an indexing system, these require checking for improper alignment. All seals must be in place and in good condition (particularly after cartridge replacement). O-rings, gaskets, hoses and all mechanical fittings should be checked for leaks.

Desiccant Suppliers
Union Carbide Corporation Molecular Science Department Moorestown, NJ 08057 (609) 778-6283 Newport Scientific, Inc. 8246-E Sandy Court Jessup, MD 20794-0189 (301) 498-6700

Blowers, Heaters, Thermocouples, Amperage

Blower rotation should be checked after maintenance is performed. Process and regeneration heaters should be checked along with the condition of the thermocouple at the hopper inlet. It is a good idea to have permanently mounted ammeters on each heater element. Amperage should be periodically checked since amperage drops can result in significant loss of heating power.

11

Drying System Troubleshooting Guide

Problem Low airflow Probable Cause 1. Plugged filters 2. Damaged airflow meter 3. Incorrect blower rotation 4. Desiccant assembly not transferring 5. Collapsed air hose 6. Plugged desiccant beds 1. Low airflow 2. Regeneration heaters not working 3. Temperature entering desiccant bed too high 4. Moist air leaking into system 5. Dew point meter incorrect 6. Contaminated desiccant bed 1. Electrical malfunction 2. One or more contaminated desiccant beds 3. Equipment too small 1. Incorrect setting 2. Low airflow 3. Hose hook up incorrect 4. No insulation 5. Heating elements burnt out 6. Equipment too small Corrective Action Inspect/clean Check/repair Check/correct Check/repair Check/replace Inspect/replace See above Check/replace Check aftercooler Check hoses, etc. Calibrate Inspect/replace Check system Inspect/replace Use larger unit Check See airflow Check Insulate Check Use larger unit

High dew point

Dew point cycling high to low Process air temperature too low

12

Chapter 4 Molding Conditions

Machine Set-up
Cylinder and Melt Temperatures
Cylinder temperature settings depend on a number of factors; e.g., size and type of machine, shot size, cycle, etc. Typical cylinder and melt temperatures for Rynite PET resins are shown in Table 3. The nozzle and melt temperatures are the most critical. Melt temperature for optimum properties varies with hold-up time. As a guide in selection of melt temperature, a temperature vs. barrel residence time grid is presented in Figure 10. The melt temperature should be checked periodically with a needle pyrometer during a molding run to be sure that the temperature does not exceed the recommended limits.
Figure 10. Processing Range: Modified PET Melt Temperature vs. Residence Time

600 310
Melt Temperature, F

300 290 280 270 260 2 4 6 8 10 12 14 16

560 540 520 500

FR. Toughened Resin

Nozzle Temperature
The nozzle temperature should be adjusted to prevent nozzle freeze-off or drool. Temperatures in the range of 270300C (520570F) should be used.

Residence Time, Min

The melt temperature processing window depends upon the resin grade, as well as the barrel residence time.

Mold Temperature

Mold surface temperature between 90 and 120C (190 and 250C) is suggested for optimum dimensional stability, surface appearance, and cycle, with the preferred range being 100120C (210250F). Table 3A shows how the preferred minimum temperature varies with thickness. High mold temperatures yield a better surface with higher gloss. High-temperature rated water hoses or oil heaters are recommended to obtain the desired

mold surface temperatures. When mold temperatures below 90C (190F) are used, the initial warpage and shrinkage will be lower, but the surface appearance will be poorer and the parts dimensional change will be greater when heated above 90C (190F). If minimum out-of-the-mold warpage is the only requirement, Rynite PET resins may be molded with surface temperatures less than 65C (150F).

Table 3 Typical Cylinder and Melt Temperatures*

Resin Series 500, 900 400, Flame retardant C F C F Rear 260290 500550 260275 500530 Cylinder Settings Center Front 260295 500560 260280 500540 265295 510560 266280 500540 Nozzle 275300 530570 260290 500560 Preferred Melt Temp. 280300 540570 270290 520550

*Melt temperature must not exceed 330C (625F).

13

Melt Temperature, C

580

Table 3A Mold Temperatures

Part Thickness mm (in) 0.75 (0.030) 1.5 (0.060) 3.1 (0.125) 6.3 (0.250) Preferred Minimum Mold Temperarure* C (F) 110 (230) 105 (220) 100 (210) 90 (190)

Screw Speed/Back Pressure

The screw RPM (speed) should be adjusted so that the screw retraction time is about 75% of the available mold closed time. The screw RPM should be slow (with little or no back pressure) in order to minimize glass fiber breakage.

Purging
Purging is essential before and after molding Rynite PET resins because many other plastics degrade at the Rynite PET melt processing temperature. Contamination of Rynite PET with other resins such as nylon, polycarbonate, acetal, polybutylene terephthalate (PBT), or polyarylate may cause molding difficulty and/or resin decomposition. The best purging materials are polystyrene, cast acrylic (the nozzle must be removed during purging) and high density polyethylene (or glassreinforced polyethylene, followed by high density polyethylene). The following purge procedure is recommended for standard injection molding equipment: A. Retract screw injection unit from sprue bushing, and keep the screw in the forward position. B. Run the screw at high RPM and pump out as much of the material as possible. Add and extrude purge compound until it comes out clean. Cylinder temperatures may have to be adjusted, depending on purge material used. C. lt is good practice to shoot several air shots at a fast injection rate to scrub walls of cylinder before switching to another resin. Care should be employed to avoid possible splatter of molten resin when this is done. The following purge procedure is recommended for hot runner systems:

*Subtract 25F for HP and SST grades.

Injection Pressure/Flow
Rynite PET resins have higher flow than glassreinforced 6/6 nylon and glass-reinforced polybutylene terephthalate under normal operating conditions. Injection pressures should be set lower than comparable settings for the above mentioned materials. The effect of injection pressure on the flow of glass-reinforced Rynite PET resins in the 0.040 and 0.100 in. (1.02 and 2.54 mm) snake flow configurations are shown in Figure 11.
Figure 11. Snake FlowRynite PET 530 Melt Temperature = 290C (555F) Mold Temperature = 93C (200F)

711 (28) 660 (26) 610 (24) 559 (22) 508 (20) 457 (18) 406 (16) 356 (14) 305 (12) 254 (10) 203 (8) 152 (6) 102 (4) 51 (2)

Flow, mm (in)

2.54 mm (0.100 in) thickness

1.02 mm (0.040 in) thickness

18 10 12 14 8 16 (56.2) (69) (76.8)(98.6) (110.4)(124.2) Injection Pressure, psi x 103 (MPa)

Fill Rate
Rynite PET resins exhibit fast set-up in the mold. To prevent premature surface freezing (which results in poor surfaces and weak weld strengths), moderate to fast fill rates (1-4 sec) should be used. Adequate mold venting must be provided to prevent part burning associated with these fill rates (see Mold Venting, page 17).

A. Shield personnel from mold. B. Raise manifold temperatures 528C (50F) above first resins melt temperature or 11C (20F) above desired Rynite PET melt temperature (but less than 310C [590F] actual), whichever is lower. C. Extrude dried Rynite PET through open mold using machine back pressure, until purge is clear. D. Drop manifold temperature to operating conditions. Purge out hot Rynite PET (12 min maximum). E. Drop pressures to usual lower Rynite PET levels.

14

Start-up
A. Start with a clean machine. B. Set the cylinder temperature to 28C (50F) below the minimum molding temperature and the nozzle at operating temperatures. Allow heat to soak in for at least 20 min. Raise cylinder temperature to the operating temperature (use Table 2 as a guide). C. Check to see if nozzle is at temperature. D. Jog screw. If screw will not rotate, allow longer soak time for cylinder temperatures. E. When the screw begins to rotate, open feed slot briefly and then close. Check the load on the screw drive. If it is excessive, increase rear zone temperature. The nozzle must be open at this time. F. Open feed slide, keep screw in forward position. Extrude melt and increase the front zone temperature if unmelted particles are seen. G. Adjusting stroke to approximate shot weight, take several air shots at the approximate overall cycle. The melt temperature should now be checked with a needle probe pyrometer. Make any adjustments in the cylinder temperatures

necessary to get the recommended melt temperature. (This procedure should be repeated when a significant cycle change occurs.) H. Bring injection cylinder forward. Start at a low injection pressure (except where short shots will interfere with part ejection) and adjust molding variables for best part appearance and maximum part weight.

Shutdown
The machine should be purged thoroughly with polystyrene or polyethylene, which cuts the time required for subsequent start-up and reduces problems of contamination. The following shutdown procedure is suggested: A. Shut hopper feed slide, while continuing to mold on cycle. B. Empty hopper, add a quantity of polystyrene or polyethylene; extrude until the screw pumps itself dry C. Leave screw in forward position. D. Shut down power supply.

15

16

Chapter 5 Mold Design

Rynite PET glass-reinforced polyester resins have been molded in a variety of molds. Insulated and hot runner molds are well suited to these materials. Owing to the low shrinkage and high flow of Rynite PET resins, prototype tools which were originally designed for higher shrinkage materials may not eject automatically. Polished cavities and well designed hot water coring produce a high gloss surface on Rynite PET molded parts. To facilitate high injection rates, also necessary for good part surface, melt flow should not be restricted. In a properly designed mold, employing standard Rynite PET operating procedures, weld strengths of these resins pose no particular problem. gates, the gate diameter should be about 4555%, of part thickness. Rectangular Gates. The gate thickness should be greater than 50% of the part thickness and the gate width should be 1.5 to 2 times the gate thickness. For both round and rectangular gates, the gate land should be short; between 0.76 and 1.52 mm (0.030 and 0.060 in).

Vents
Molds must be adequately vented in order to prevent localized burning of the parts, damage to the mold, poor weld line strength and to allow easier filling of the cavity. The vents should be less than 0.025 mm (0.001 in) deep and as wide as practical. About .76 mm (0.030 in) from the cavity the vents should be deepened to about 3.2 mm (0.125 in) and extended to the edge of the mold.

Sprues and Runners

The entrance diameter of the sprue should be in the range of 3.81711 mm (0.150.28 in). The smallest-diameter sprue should be used where possible. Hot sprue bushings have been used successfully with Rynite PET resins and should be considered. Full round or trapezoidal runners are recommended. Runner diameters in the range of 3.26.4 mm (0.1250.250 in) have been successfully used with Rynite PET resins. In certain molds, runners of larger diameter may be necessary. However, due to the excellent flow characteristics of Rynite PET resins, the smallest diameters for runners should be considered first. Length should be as short as possible to minimize rework. Layout of runners should be balanced and generously radiused for smooth and uniform melt flow.

Undercuts and Taper

Because of the low elongation of glass-reinforced polyester, undercuts should be avoided. A taper (draft) of 12 to 1 on ribs, bosses, sides and sprues should be satisfactory.

Runnerless Molds
Properly designed modified insulated runnerless and hot runner molds are well suited for Rynite PET resins. Numerous Rynite PET parts, diverse in size, complexity and end use, are being mass produced from runnerless systems. All Rynite PET resins are runnerless candidates. Melt temperature, hold-up time (including runnerless manifold residence time) and streamlined melt flow path are critical factors. Melt temperature and hold-up time guides for specific resins are discussed in the first section of Chapter 4 (Molding Conditions, Cylinder and Melt Temperatures).

Gates
The number and location of the gates have a significant effect on the orientation of the glass fibers and therefore on the warpage of the part. Careful consideration should be given to these two variables. Suggested gate dimensions are: Round Gates. Tunnel gates can be used provided the gate diameter is greater than 0.508 mm (0.020 in); 0.020 in is a minimum and can only be used with short land length. In three-plate molds, the gate diameter should be less than 2.29 mm (0.090 in) to ensure automatic degating. For round

Wear
Experience to date indicates wear can be minimized by properly hardened tool-steel cavities, cores, runner systems and sprue bushings. Cavities must be vented at welds to minimize pitting from high temperature gas entrapment. Also, gates (blocks) are subject to considerable heat buildup and loss of hardness as a result of the fast injection rates used in processing glass-reinforced polyesters.

17

Specific recommendations on materials of construction can be found in the Molding Equipment Section.

Tolerances
Tolerances for parts molded of Rynite PET resins vary according to the complexity and wall thickness of the design. Predicting dimensional uniformity of

glass-reinforced resins can be difficult as it will depend to a large degree on glass fiber orientation in the part. The tolerances in Table 4 (based on the SPI format) do not represent hard and fast rules applicable to all conditions, but rather the consensus of molders for what may be achieved under normal conditions.

Table 4 A Guide to Tolerances of Rynite PET Glas-Reinforced Polyester Resins

Note: The commercial values shown below represent common production tolerances at the most economical level. The fine values represent closer tolerances that can be held but at a greater cost.

Drawing Code

Dimensions, Inches 0.000 0.500 1.000 2.000 3.000 4.000 5.000 6.000

Plus or Minus in Thousandths of an Inch 1 2 3 4 5 6 7 8 9 10 11 12

B J

F C

A = Diameter (see Notes #1 & #2) B = Depth (see Note #3) C = Height (see Note #3)

co
fin e

mm

L F

er

cia

6.000 to 12.000 for each additional inch add (in.) D = Bottom Wall (see Note #3) E = Side Wall (see Note #4) 0.000 to 0.125 F = Hole Size Diameter (see Note #1) G = Hole Size Depth (see Note #5) Draft Allowance per side (se Note #6) 0.125 to 0.250 0.250 to 0.500 0.500 & Over 0.000 to 0.250 0.250 to 0.500 0.500 to 1.000

Typical, inches 0.002 0.004 0.004 0.002 0.003 0.003 0.004 0.003 0.004 0.005 1/21

Reference Notes
1. These tolerances assume a mold temperature 93C (200F). Annealing at 150C (300F) will cause 0.1% overall dimensional change. 2. Tolerances based on 3.2 mm (1/8") wall section. 3. Parting line must be taken into consideration. 4. Part design should maintain a wall thickness as nearly constant as possible. Complete uniformity in this dimension is impossible to achieve. 5. Care must be taken that the ratio of the depth of a cored hole to its diameter does not reach a point that will result in excessive pin damage. 6. These values should be increassed whenever compatible with desired design and good molding techinique.

SI conversion
Inches x 25.4000 = millimeters

18

Chapter 6 Other Considerations

Rework
Figure 12 shows how several levels of rework affect the tensile strength properties of Rynite PET 530 and 545, as related to the number of passes through an injection molding machine. Although the drop in tensile strength is minimal at both 25% and 50% regrind levels, higher rework loadings (particularly 100%,) will reduce the glass fiber length in the molding, leading to a significant loss of tensile strength. Thus, to prevent fiber damage and to retain maximum physical properties, the addition of rework should be kept as low as possible, preferably less than 25%. Rework should always be ground hot to minimize glass fiber breakage. In addition, grinder screens should have a hole size of 5/16" or greater and the cutting blades should be kept sharp to reduce fines. Limited experience has shown that carbide-tipped blades exhibit good performance and durability.

Lubricants
The addition of surface lubricants to Rynite PET resins is generally not recommended, because they may cause a reduction in the physical properties of the molded part.

Warpage
Warpage is caused by non-uniform shrinkage of the resin. The non-uniform shrinkage may be due to: Non-Uniform Wall Thickness of the Part. Whenever possible, parts should be designed with a uniform wall thickness; thick parts should always be cored in order to minimize higher shrinkage. Mold Design. Typically round parts should be center-gated and long flow parts should be end-gated.

Figure 12. Regrind vs. Tensile Strength

Rynite PET 530 % Initial Tensile Strength 100 % Initial Tensile Strength

Rynite PET 545 25% Regrind/75% Virgin 100

25% Regrind/75% Virgin

50% Regrind/50% Virgin

90

50% Regrind/50% Virgin

90

80 1 2 3 4 Number of Passes 5

80 1 2 3 4 Number of Passes 5

19

Processing Conditions. The mold and cavity temperatures must be carefully controlled to prevent uneven cooling of any part prior to ejection. Usually a cold mold will temporarily reduce warpage but may reduce surface gloss. See Troubleshooting Guide for a complete list of processing variables affecting warpage. Anisotropic Shrinkage. Anisotropic shrinkage (difference in shrinkage in the flow and transverse directions, see Tables 5 and 6) probably contributes more to warpage problems in glass-reinforced resins than any other factor. Anisotropic shrinkage most often arises because of orientation of the glass fibers in the direction of flow which, in turn, restricts normal resin shrinkage. Therefore, any condition that can create a random distribution of the glass fibers will reduce the warpage, i.e., abrupt change in flow direction, multiple gating, different gate location, etc.

glass fibers, part thickness and processing conditions. Rynite PET glass-reinforced resins shrink less in the flow direction than in the transverse direction. Shrinkages listed in Table 5 are intended as a guide for estimating out-of-mold dimensions as a function of part thickness from a hot (104C, 220F) mold. The effect of mold temperature on shrinkage is demonstrated in Table 6 for a 1.58 76.2 127 mm (1/16 3 5 in) plaque. As with many other semi-crystalline plastics, the fast cooling of a part in a low-temperature mold does not permit development of full crystallinity This leads not only to less shrinkage, but a less dimensionally stable part. Upon annealing, the coldmolded part will shrink perceptibly whereas a Rynite PET part molded at 104C (220F) will change less than 0.1%. For complicated precision parts, prototype molds (cavities) should be utilized to obtain more accurate dimensional data.

Mold Shrinkage
The mold shrinkage of Rynite PET, glassreinforced resins depends on the orientation of the

Table 5 Effect of Part Thickness on Mold Shrinkage (% units) Plaque: End-gated 101.6 x 254 mm (4 x 10 in) for 6.4 mm (1/4 in)
Thickness Mold Temp. Rynite PET 530 Rynite PET 430 Flow Length 0.2 0.3 Transverse Width 0.9 1.0 Rynite PET 545 Flow Length 0.2 0.2 Transverse Width 0.8 0.9 Rynite PET 555 Flow Length 0.2 Transverse Width 0.7 Rynite PET 935 Flow Length 0.4 Rynite PET 940 Rynite PET FR-530

mm 3.2 6.4

(in) (1/8) (1/4)

TransTransTransverse Flow verse Flow verse Width Length Width Length Width 0.8 0.2 0.7 0.2 0.9

93 (200) 104 (220)

Table 6 Effect of Mold Surface Temperature on Mold Shrinkage (% units)* Plaque: End-gated 1.58 x 76.2 x 127 mm (1/6 x 3 x 5 in)
Mold Temp. Rynite PET 530 Rynite PET Rynite PET 430 545 Rynite PET 555 Rynite PET 935 Rynite PET FR-530 Rynite PET SST 35 Rynite PET 415 HP Rynite PET 430 HP

F 48 91 93 104

TransTransTransTransTransTransTransTransFlow verse Flow verse Flow verse Flow verse Flow verse Flow verse Flow verse Flow verse Length Width Length Width Length Width Length Width Length Width Length Width Length Width Length Width 0.35 0.75 0.88 0.07 0.13 0.14 0.29 0.75 0.77 0.10 0.12 0.29 0.6 0.16 0.24 0.3 0.6 0.09 0.15 0.35 0.75 0.18 0.98

(100) 0.09 (195) (200) 0.15 (220) 0.16

20

Summary of Variables Affecting Toughness and Strength

The variables that may cause a reduction in the toughness and strength of Rynite PET glassreinforced polyester resins include: 1 . Moisture in the virgin or rework resin. For optimum properties, Rynite PET resins, virgin and rework, must be dried and maintained at moisture levels less than 0.02% during processing. 2. Long melt residence times (>10 min). 3. Too high or too low melt temperature (see Figure 10). 4. Combination of all three above. The toughness of Rynite PET glass-reinforced resins depends upon moisture, hold-up time and melt temperature. 5. Improper mold venting. 6. Glass fiber length. In order to minimize glass fiber breakage: Use minimum allowable screw speed. Use little or no back pressure. Keep the rework low (25% or less). Use proper rear zone temperature. 7. Contaminated rework or molding equipment. 8. The use of additives, e.g., certain types of mold release lubricants, pigments, etc. 9. Part designsharp corners, non-uniform wall thickness.

Be particularly alert during purging and whenever the resin is held in the machine at higher than usual temperatures or for longer than usual periods of timeas in a cycle interruption. Pay particular attention to the section on Molding Conditions beginning on page 13. In purging, be sure that the high volume (booster) pump is off and that a purge shield is in place. Reduce the injection pressure and jog the injection forward button a few times to minimize the possibility that trapped gas in the cylinder will cause splattering of the resin. If polymer decomposition is suspected at any time, a purge shield should be positioned, the carriage (nozzle) retracted from the mold and the screw rotated to empty the barrel. After the screw starts to rotate, the feed throat should be closed and then a suitable purge compound introduced. The temperature can then be gradually lowered and the machine shut down. If jogging the injection or screw rotation buttons does not produce melt flow, the nozzle may be plugged. In that case, shut off cylinder heats and follow your established safe practices. Always assume that gas at high pressure could be trapped behind the nozzle and that it could be released unexpectedly. A face shield and protective long-sleeved gloves should be worn at such times. In the event molten polymer does contact the skin, cool the affected area immediately with cold water or an ice pack and get medical attention for thermal burn. Do not attempt to peel the polymer from the skin. B. Since Rynite PET resins are dried at high temperature, contact with hot hoppers, ovens or air hose lines could result in severe burns. Insulation of these components will reduce this possibility. C. Small amounts of gases and particulate matter (i.e., low molecular weight modifiers) may be released during the molding, purging or drying of Rynite PET. We recommend adequate local exhaust ventilation be provided during the processing of Rynite PET. We have calculated that a ventilation rate of 75 cubic feet of air per minute per pound of resin processed per hour will keep the concentration of particulates well below the OSHA (15 mg/m3) and TLV (10 mg/m3) exposure limits for nuisance dust while being processed at the maximum recommended times and temperatures (molding, purging, and drying).

Safety Precautions
While processing Rynite PET resins is ordinarily a safe operation, consideration should be given to the following: A. Since Rynite PET resins are molded at high temperatures, the molten resin can inflict severe burns. Furthermore, above the melting point, moisture and other gases may generate pressure in the cylinder which, if suddenly released, can cause the molten polymer to be violently ejected through the nozzle. To minimize the chance of an accident, the instructions given in this manual should be followed carefully. Potential hazards must be anticipated and either eliminated or guarded against by following established proceduresincluding the use of proper protective equipment and clothing.

21

D. Rynite PET resins, like all thermoplastic polymers, can form gaseous decomposition products with long hold-up times at the maximum recommended melt temperatures. This is accelerated above 330C (625F). E. Adequate local exhaust ventilation should also be provided during the regrind operation. F. Prior to cleaning of any barrel that contains Rynite PET resins, the machine should be thoroughly purged with polyethylene or polystyrene. G. If Rynite PET resin is accidently purged over the heater bands, it should be removed and not allowed to degrade.

H. Adequate local exhaust ventilation must be provided during the burnout of any equipment that contains Rynite PET resin; e.g., nozzles, etc. I. Granules of Rynite PET present a slipping hazard if spilled on the floor. They are cube shaped and have a low coefficient of friction. They should be swept up immediately. For more detailed information on safety, see the Rynite PET Safety Precautions During Molding flyer (E-75332 7/87).

22

Chapter 7 Troubleshooting Guide

Problems Suggested Remedies
(Try in order listed) Brittle Parts Short Shots Voids Poor Part in Weld Sprue Part Surface Parts Burning Warpage Strength Sticking Sinks Sticking Appearance

Ensure resin is dry Change injection pressure Increase injection speed Decrease injection speed Increase screw forward time Decrease screw forward time Check melt temperature Increase mold temperature Increase nozzle temperature Increase gate size Increase vent size Use reverse taper nozzle Decrease hold-up time Change cycle Check pad size (cushion) Repair mold Increase taper Change gate location Reduce rework level Balance mold temperature Check puller design Check for contamination Check for voids Decrease mold temperarture

1 2 3 2 4 3 3 3 2

1 3 2 4 3 3 2 2 2 2 5 4

4 5

6 5 3 1

5 1

3(a) 1

7 6

6 7

5 2 4 4

8 7

3 4 1 1 5 6 6 4 1 7 5 6 7 5 7 4 1 5 6 9 4 6

23

Molding Data Record

Job Operators Engineers Nozzle # Pressures, psi (kp/cm2) Cycle Times, sec Weights, g Press No. Temperatures, F (C) Screw Used Mold Description Machine Setup Instructions

Special Instrumentation

Safety Check

Run Number

Lot Number

Injection 1st Stage Injection 2nd Stage Clamp, Tons

Ram in Motion Screw Retraction

Date Time
Hold Melt

Part Only Full Shot Booster Overall Pad, in Open RPM

Mold
Injection Movable Nozzle Fixed Center Front Back Rear

Resin

Remarks

24
Comments on Molding Operation, Startup, etc.

Page No.

Identity and Trademark Standards

Guidelines for Customer UseJoint ventures and authorized resellers
Only joint ventures and resellers who have signed special agreements with DuPont to resell DuPont products in their original form and/or packaging are authorized to use the Oval trademark, subject to the approval of an External Affairs representative.

Guidelines for Customer UseAll other customers

All other customer usage is limited to a product signature arrangement, using Times Roman typography, that allows mention of DuPont products that serve as ingredients in the customers products. In this signature, the phrase, Only by DuPont follows the product name. Rynite PET only by DuPont or Rynite PET Only by DuPont

A registration notice or an asterisk referencing the registration is required. In text, Only by DuPont may follow the product name on the same line, separated by two letter-spaces (see above example). When a DuPont product name is used in text, a or a reference by use of an asterisk must follow the product name. For example, This device is made of quality DuPont Rynite PET polyester elastomer for durability and corrosion resistance. Rynite PET is a DuPont registered trademark. Rev. August 1995

Rynite PET

thermoplastic polyester resin

Start with DuPont

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