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Content

XANTAR®, a Brand of Mitsubishi Engineering Plastics Globalsupply 02 Innovations 02 Partnership 02 Quality&consistency 02 Sustainability 02 Productrange 02

XANTAR® Innovations XANTAR®LaserDirectStructuring(LDS) 04 XANTAR®XtraRobustModified(XRM) 05 XANTAR®AntiMicrobial(AM) 05 XANTAR®Cfortraininteriorcladding 06 XANTAR®Cforcabletrunking 07

XANTAR® Applications E&E 08 Automotive 12 GeneralIndustries 13 Extrusion 13

Typical properties of XANTAR®

XANTAR®Polycarbonate 14 XANTAR®C,BlendofPCandABS 15 XANTAR®E,BlendofPCandPolyester 17 XANTAR®,XANTAR®CandXANTAR®E 17

ULrecognitions 18

Designing with XANTAR®

ChoosingtherightXANTAR®grade 20 Productdesign 21 Toolingdesign 22 Secondaryoperations 23

Mitsubishi Engineering Plastics

Contact information MEP

XANTAR® Attachments Gradeselectionguide

02-03

04-07

08-13

14-19

20-24

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Global supply

AsbrandofMitsubishiEngineeringPlastics,XANTARhasawell-established,fullybackwardintegratedsupplychainwithstrongglobalsupportateachstage.Thankstothesestrongsupplychains,outstandingcustomerservicelevels,andworld-classtechnologyprogram,allonaglobalscalewithfullandagilelocalcoverageatthehigheststandard,weareareliablelong-termpartnertocreateinnovativeaddedvalueforalldemandingapplications.

Innovations

Facingthechallengesofhigh-endmarketsandgettingthemostoutofapolycarbonateresinrequiresmaterialsknowledgeandexperiencethatgoesbeyondthekeyengineeringskillsofmostcustomers.WithXANTAR,weareabletooffercontinuedsupportandtheexpertiserequiredtosimplifyandshortenyourdevelopmenttimes,toreducesystemcosts,andtomakeyourproductssuccessful.Inaddition,wecontinuetoinvestinthedevelopmentofnewinnovativematerialsthataddressthehighmarketstandardsandneeds.Ourimpressivecustomerportfolioisclearproofofourabilitytodeliverbothinnovativeconceptsandsolutionstohelpmeetthechallengesourcustomersface.

Partnership

Thesuccessfultranslationofyourvisionintoviableproductsandsolutionsstartswithin-depthunderstandingofyourneedsandtheapplicationitself.Partnershipanddiscretionarekey,andherewehaveatrackrecordofmaterialsknowledgeandexperiencebuiltovertwodecades.

Quality & consistency

Inengineeringplastics,productconsistencyisoftheutmostimportance.Ahighproductconsistencyofthefeedstockcontributestohigherproductivityandlowerprocessingscraprates.DuringtheproductionofXANTARPolycarbonate&Blendsweenhanceboththein-lotandlot-to-lotconsistencybycontinuouslymonitoring,post-blendingandimplementingallnecessaryimprovements.Fromdesigntofinalproduction,ourworkingproceduresarefullycompliantwithISO9001andISO/TS16949QualityStandards,whichalsohelptodeliverconstantqualitywhilstminimizinganyfluctuationsorchanges.

Sustainability

Concernfortheenvironmentisfullyintegratedinourinnovationandproductionprocesses.AllourproductscomplywithEurope’sRoHSandWEEEdirectivesandsimilarstandardsthatarecurrentlyindevelopmentaroundtheworld.Productionprocessesandmaterialformulationsareoptimisedforresponsibleuseofnaturalresourcesandminimizetheimpactontheenvironment.XANTARPolycarbonate&Blendsofferhalogenfreesolutionsforthevastmajorityofproductsandapplicationsandwearecontinuouslyexpandingourportfolioofgreenproducts.

Product range

ThecomprehensiveXANTARportfoliocomprisesallcommontypesofpolycarbonate,specializedintheirdiversityandcustomizationtospecificmarketrequirements.XANTARCblendsofPC/ABSandXANTARE(PC/Polyester)extendthescopewhilemaintainingthesamehighqualitystandardsofXANTARproducts(Table1).MitsubishiEngineeringPlasticshasthecapabilitytodevelopgradestomeetnewrequirements,eitherintermsofperformance,improvedproductivityand/orreductionofsystemcosts.ThesuperiorpropertiesandprocessabilityofXANTARCgrades,andnewmaterialinnovationssuchasXANTARLDS,XANTARAMandXANTARXRMdemonstratethatMitsubishiEngineeringPlasticshastheabilityandresourcestodeliverresultsandbeyourglobalpartnerforinnovativeaddedvalue.

XANTAR®,a Brand of Mitsubishi Engineering Plastics

XANTAR,abrandofMitsubishiEngineeringPlastics,isafamilyofhigh-endengineeringplastics.XANTARwasestablishedovertwodecadesago–andhasbeensuccessfulsincetheninasignificantnumberofhigh-endmarketsegments.ThisbrochureprovidesanoverviewoftheXANTARproductrange,anddemonstrateshowweareyourglobalpartnerforinnovativeaddedvalueinthenextdecades.

In-depthunderstandingoftheapplicationsandpartnershiparekey

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Table 1. XANTAR, XANTAR C and XANTAR E commercial grades coding.

XANTAR C and XANTAR E

CM 206 U Which blend

Cx xxx x = PC/ABS

Ex xxx x = PC/Polyester

CM 206 U Major characteristics

xM xxx x = injection moulding

xF xxx x = flame retardant

xE xxx x = extrusion

CM 206 U Temperature resistance

xx 1xx x = vicat < 110 °C

xx 2xx x = vicat ≥ 110 °C

xx 4xx x = vicat ≥ 120 °C

xx 5xx x = vicat ≥ 130 °C

xx 6xx x = vicat > 135 °C

CM 206 U Reinforcement

xx x0x x = unreinforced

xx x2x x = 10% GF reinforced

xx x4x x = 20% GF reinforced

CM 206 U Further classification

xx xx5 x = low temperature, high impact

xx xx6 x = standard

xx xx7 x = flame retardant

CM 206 U Additional information

xx xxx U = UV stabilized

XANTAR

XXX NN YY ZZ Special additive package (no indication: general purpose grade)

F = FR (flame retardant): UL 94, V-0, 3.0 mm, Transparent

FC = FR; V-0, 1.5 mm

G2F = 10% GF, FR (V-0, 1.5 mm)

G4F = 20% GF, FR (V-0, 1.2 mm)

G6F = 30% GF, FR (V-0, 1.5 mm)

G8F = 40% GF, FR (V-0, 1.5 mm)

XXX NN YY ZZ Indication of melt viscosity

18 = extremely low viscosity 23 MFR

19 = very low viscosity 16 MFR

22 = low viscosity 10 MFR

24 = medium viscosity 7 MFR

25 = high viscosity 5 MFR

27 = very high viscosity 3 MFR

XXX NN YY ZZ General purpose additive package

R = mould release

U = UV stabilized

UR = U + R

SR = Steam resistant + mould release

XXX NN YY ZZ Additional material characteristic

FD = Food and drug approved

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XANTAR® Innovations

1GHz 3GHz

DielectricConstant(ε’)

LossTangent(tanδ)

DielectricConstant(ε’)

LossTangent(tanδ)

XANTARLDS3710 2,8±0,05 0,0088 2,8±0,05 0,0078

XANTARLDS3720 2,8±0,05 <0,009 2,8±0,05 0,0049

XANTARLDS3730 3,0±0,05 <0,009 3,0±0,05 0,0053

Facingthechallengesofhigh-endmarketsandgettingthemostoutofapolycarbonateresinrequiresmaterialsknowledgeandexperiencethatgoesbeyondthekeyengineeringskillsofmostcustomers.WithXANTAR,wecontinuetoinvestinthedevelopmentofnewinnovativematerialsthataddressthehighmarketstandardsandneeds.In-depthunderstandingoftheapplicationsandpartnershiparekey,andourportfolioofinnovativematerialsisproofofourcapabilitiesandcommitmenttodelivertherightresults.

XANTARLDSisthehighest-impactmaterialavailableforlaserdirectstructuring

Table 2. High antenna performance thanks to excellent

combination of dielectric constants and loss tangents for

various XANTAR LDS grades.

XANTAR® Laser Direct Structuring (LDS)

TheXANTARLDSportfolioisideallysuitedforintegratedmobilephoneantennasfromantennacarriers(Figure1)tofullyintegratedantennasinthehousingorframe.Theapplicationareahasnowbeenextendedtoantennasinlaptopsandnotebooks.

FullColourcustom-madePC-andPC/ABS-basedgradesareavailablethatenableselectiveelectrolessplatingbymeansoflaserdirectstructuring(LDS)tointegrateelectriccircuitsintomouldedparts.

BenefitsofXANTARLDSforlaserdirectstructuringtechnology(basedonjointdevelopmentwithLPKF):

OptimizedforLDStechnology:- Highest-impactmaterialavailableforlaserdirect

structuring- Halogenfreeflameretardant- Resolution(line/space)downto100microns- Extremelywellsuitedforantennasinmobile

phonesandnotebooks- FullcolouravailabilityforPC-andPC/ABS-

basedLDSgrades

High-performance/robustness:- DielectricconstantofPC/ABShelpstoassure

highantennaperformance(seeTable2)- Outstandingimpactstrengthoutperforms

competitivePC-blends

Figure 1. The full colour capability and excellent surface quality

of XANTAR PC and XANTAR PC/ABS LDS grades opens up

endless aesthetic design possibilities.

AdvantagesofinnovativeLDStechnology:

- Higherflexibilitycomparedtoothermouldedinterconnectdevice(MID)technologies,providingfastertime-to-market

- Enables3Dshapesandelectricalconnectionssimultaneously

- Suitableforrelativelysmallsurfaceareas- Onlythreeprocesssteps:moulding,laser

processing,metallization

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XANTAR® Xtra Robust Modified (XRM)

Forthosedemandingapplications,whereconventionalgradesmaynotmeetallrequirements(Figure2),wehavedevelopedanewfamilyofimpactmodifiedflameretardantPC,whichiscompletelybasedonaninnovativeadditivetechnology:XANTARXRM.Thisnaturallybrightwhitegradecanbecoloredeasilyandexhibitsauniquecombinationofproperties,exceedingthoseofconventionalPCandPC/ABSgrades:

– Noplasticizingeffect,highultimatetemperatureuse,equaltoPC

– Excellentlowtemperatureimpact,downtoe.g.-40°C

– Outstandingdimensionalstability,excellentcreepbehavior

– UL94V-1,V-0and5Vflammabilityratings,offeringsecuritytoapplications

– Excellentelectricalperformance– Excellentenvironmentalstresscracking

resistance,outperformingeventhemostrobustPC/ABSgrades

– Offeringlongtermreliability,withsecondtononeUV-,weatherability,hydrolyticallyandthermo-oxidativestability,outperformingeventhemostrobustPC/ABS

– Easyprocessing,nojuicingoroutgassing

XANTARXRMiscompletelyfreeofchlorine,bromine,phosphorousandantimony,enhancingthegreenimageofitsapplications,andisavailableinbothreinforcedandnon-reinforcedgrades.

XANTARXRMistheonlychoiceifyourequirehighimpact,securedlowandhightemperatureperformance,chemicalresistance,stabilityandreliability.

Figure 2. XANTAR XRM (glass reinforced XANTAR RX 5010)

meets the stringent requirements for MCCB’s.

XANTAR® Anti Microbial (AM): inhibits bacterial growth

Increasingly,todaythereisasubstantialriskofbacterialinfectionsinpublicbuildingsandtransportandanyotherplaceswherelargenumbersofpeoplegatherinaconfinedspace.Hospitalsandnursinghomesneedtoexerciseparticularcautiontoprotectagainstnosocomialinfections.Notorious‘superbugs’suchasMRSAbutalsoESBLbacteriaareknownfortheirstrongresistanceagainstcertainantibioticsandthereforeposearealthreatfororiginatingHospitalAcquiredInfections.

XANTARAMisauniquenewproductthatoffersahighlevelofmicrobialresistancethroughpreventionofcross-contaminationbyeffectivelyreducingbacteriapopulationsandinhibitingthegrowthofpathogenicbacteriaonplasticsurfaces.XANTARAMisformulatedwithasilver-basedinorganicantimicrobialcompoundthatcontrolsthegrowthofgram-negativeandgram-positivebacteriaonthesurfaceoftheproduct.Typicalapplicationsarefoundinconsumerdurables,sanitaryproductsandmedicaldevices.

XANTARAMoffersahighlevelofmicrobialresistance

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Figure 4. Innovative train cladding with XANTAR C CE 407.

Figure 3. XANTAR AM grades inhibit bacterial growth

(ISO 22196 / JIS Z 2801).

XANTAR® C for train interior cladding

Safetyistheoperativewordforpublictransportation.Thedemandsarenotlimitedtoaviationbutarealsoapplicabletotrain,metro,tramandbustransport.FlameretardantXANTARCnowhasanumberofgradestomatchthebroadscopeofEurope’slegislationinthepublictransportsector.XANTARCisflameretardantanditalsomatchesdemandsforsmoketoxicityandsmokedensity.Thisensuresthatintheeventofafire,peoplewillnotdiebecauseofinsufficientevacuationtimesotheyareunabletofindasafeexitorsufferfromsuddenasphyxiation.

BenefitsofXANTARCextrusiongradesforpublictransport(Figure4):

DesignandAssembly

- Low-weightsolutionforinteriorcladding- Designfreedom:doublecurvedsurfacespossible- Modularassemblyforquickinstallationand

turnaroundtimes- Recyclable,environmentallyprogressivesolution- Excellentsounddampingproperties

Safety

- Flameretardant(accordingtoUL94V-0and5VB)- Compliantwithrailwayspecificationsforfireand

toxicity(accordingtoDIN5510/NF-F16-101,etc.)

- Bromine-freeandchlorine-free(accordingtoVDE0472part815)

- High-impactsheet,facilitatingvandal-proofsolutions

Maintenance

- WithoptionalPTFEtoplayerforanti-graffitiandeasycleaning

XANTARAMhasbeentestedandevaluatedaccordingtothewidelyacceptedstandardsISO22196/JISZ2801andASTME2149.ThegradesXANTARCRC3800(PC/ABS)andXANTARRX3812(PC),provideprotectiongreaterthanlog3(i.e.=bacteriakillexceeding99.9%),accordingtoISO22196/JISZ2801,seeforinstanceFigure3.XANTARAMisdeliveredasready-to-usecompoundsinallstandardavailablecolours.

Theintroductionanduseofantimicrobialproductsmaybesubjectedto(inter)nationallegislationforregistrationofbiocides.Forfurtherinformation,pleasecontactourTechnicalCenterinGeleen,TheNetherlands.

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XANTAR® C for cable trunking

Firesafetyandenvironmentalissueswithcurrentcablemanagementsystemshavepavedthewayforalternativeconstructionmaterials.Today,oneofthemostwidelyusedchlorine-freeandbromine-freeflameretardantalternativesisextrudablePC/ABSBlendsandPC.Benefitsare:

- Self-extinguishingaccordingtoUL94V-0and5VB

- Halogen-freeaccordingtoVDE0472part815- LowsmokedensityandtoxicityNFF16-101/102

(F2)- CompliantwithEN50085andNFP92-507(M1)- A“green”alternativeforPVC- Recyclable,eco-progressivesolution- Lightweightsolutionvs.aluminiumorsteel

trunking

- Processingwithhighoutputandhighqualityperformance

- Lowoutgassing,lowdeposittendency

XANTARCisrecommendedforinstallationtrunkingandslottedtrunking,deskcablemanagement,andcableconduitandchannel(Figure5).Versatile,easytoprocessextrudableFRPC/ABSgradesare:

-XANTARCCE407-XANTARCMC3435

BothgradescomewithafullYellowCardandhavebeenratedwithvariouscertificatesregardingflameretardancyandtoxicity.

Figure 5. XANTAR C CE 407 and XANTAR C MC 3435 have a

successful track record in halogen-free installation trunking.

XANTARandXANTARChaveanumberofgradestomatchthebroadscopeofEurope'slegislationinthepublictransportsector

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E&E applications

Cash dispensers (ATM)

DemandingapplicationssuchasATMsrequireacombinationofmechanical,flameretardantandelectricalpropertiesalongwitheasyprocessing.XANTARandXANTARCgradeshaveproventobetheprimechoiceofmaterialsfortheseapplications(Figure6).Thankstotheirexcellentimpactresistance,colourabilityandpaintability,UL94V-0and5Vratings,aswellaselectricalproperties,theynotonlymeetthestringentrequirements,butalsohelptofurtherreducesystemcosts,forinstancebyreducingthenumberofparts.OtherspecialinnovativeXANTARgrades,suchassemi-conductiveandlowfrictiongrades,areideallysuitedforinteriorhighendtechnicalcomponents.

Figure 6. Cash dispenser (ATM), made possible by various

XANTAR and XANTAR C grades.

XANTAR® Applications

Thankstotheirexcellentmechanical,thermalandelectricalproperties,XANTAR,XANTARCandXANTAREgradesareverywidelyandsuccessfullyusedinindustrysegmentssuchasElectrical&Electronics(E&E),Information&CommunicationTechnology(ICT),Automotive,andGeneralIndustries.

Mobile phones and accessories

Housingsformobilephonesmusthavehighimpactstrengthtoavoidbreakageofthehousingandtoprotecttheenclosedelectronicsintheeventofanaccidentaldrop.Atthesametime,visualappearanceisanimportantsellingtoolforamobilephone.

MitsubishiEngineeringPlasticsoffersXANTARandXANTARCgradeswhichhavebeendevelopedspecificallytomeetthehightechnicaldemandsofthinwalledmouldings.XANTARandXANTARCprovidegoodflowproperties,impactresistance,surfacequalityand(forslidingparts)excellenttribologicalproperties.

MaterialrequirementsforchargersareprescribedbyindustrystandardswhichdemandV-1flammabilityaccordingtoUL94andpassingballpressuretestat125°C.Furthermore,chemicalresistanceandprocessingperformanceareimportant.MitsubishiEngineeringPlasticshasdevelopedspecificmodifiedXANTARgradesthatfulfilalltheserequirements(Figure7).

Figure 7. XANTAR MX 1004 is specifically designed to meet the

demanding requirements for mobile phone charger housings.

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Smart metering

Withtheinternationalderegulationoftheenergymarketsandtheincreasingdriveforenergyefficiency,thereisavastdemandforsmartandintelligentmetersforelectricity,gasandwaterthatcanbeaccessedremotely.In-depthapplicationknowledge,proventrackrecordsinforinstancee-metersandenclosures(Figure9,bottom),andinteractivepartnershipalongtheentirevaluechainhaveresultedinXANTARandXANTARCgradesbeingfullyapprovedinmajorsmartmeterreplacementprojects,forinstanceinseveralimportantEuropeanvenues(Figure8).ThefocustoproactivelycreateadditionalvalueforourcustomersisunderpinnedbytheFrost&SullivanCustomerValueEnhancementAwardpresentedtoMitsubishiEngineering-Plastics.

Bothexistinggradesaswellasnewlydevelopedstabilizedgradesmeetingenhancedrequirementshavebeenintroduced,rangingfromtransparentFRXANTARgrades(UL94V-0@2mm),highflowXANTARCgradescombiningmechanicalintegrityandexcellentsurfaceappearancetohighHDT(145°C)glassreinforcedgrades.Inlinewithoursustainabilityfocus,allmaterialsuseeco-friendlyflameretardanttechnologies.

Figure 8. Smart e-meters, replacing conventional e-meters

across European venues, enabled by XANTAR C MC 3433, high

HDT XANTAR G2F 23 R and specially developed transparent

XANTAR RX 2124.

XantarisfullycompliantwithISO9001andISO/TS16949QualityStandards

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Power distribution; wiring accessories, installation & industrial control

WehavebeensupplyingallmajorproducersbothinandoutsideEuropeformanyyears.OurPCandPC/ABSBlendsmeetthespecificneedsoflocalindustries:

- halogenfreeflameretardantsystemsfor960°CGWFI,775°CGWITandV0requirements

- thermalpropertiesandflammabilityrequirementsmeetingstandardsforwiringaccessories

- excellentaestheticsprovidinghighclasssurfacequality

- optimalUVresistanceindifferentlightcolourshades(Figure9,top)

- electricalpropertiesadequateforspecificlowvoltageswitchgearapplicationslikeauxiliaryswitches(Figure9,middle)andMCCB’s(Figure2)

Relevantgradesarecertifiedaccordingtothestandardsfortransportationandbuildingindustry.Afullrangeofproductsisavailableforenclosureandcabinetapplications,rangingfromlowviscouscrystalcleartowardsflameretardantandglassreinforcedcolouredtypes(Figure9,bottom).

ThePowerDistributionsegmentisruledbyregionalandlocalstandardsandnorms.Becauseweunderstandandrespondtotheneedsoftheindustry,ourXANTARandXANTARCproductportfoliocontainsinnovativematerialsandspecialtiesthatexcelindistinguishingfeaturessuchas:

- improvedstresscrackingresistance- highLTimpactstrengthincombinationwith

UL94V-0(Figure2)- highproductivityandconsistency- antibacterialproperties

Intoday’scompetitivemarkets,optimizedproductionprocessesareessential.Weofferacombinationofglobalreach,extensiveapplicationknowledgeandacompleterangeofengineeringmaterialsforinstallationcomponentsthathelpsyoutoachievelogisticsandproductionrationalisationsoyoucanprovideyourcustomersinturnwithacompetitiveedge.

Figure 9. Top: switches made from XANTAR C MC 3700.

Middle: auxiliary switch, XANTAR MX 1094.

Bottom: enclosures composed of non-reinforced,

XANTAR 22 UR and XANTAR FC 22 UR,

and reinforced grades, XANTAR G2F 23 R

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Lighting

Luminaries(Figure11)inindustrialenvironmentsarerequiredtobewaterproof(IP66/IP67)andhaveahighimpactresistance,inadditiontothestandardcriteriaofhightransparency,goodUVperformanceandflammabilitypropertiesaccordingtoIEC/EN60598.Forfluorescenttubecovers(Figure11),XANTARfulfilstheserequirements.Tooptimizethecostofthecover,manufacturerstrytodesignforthethinnestpossiblewallsections.Ingoingbeyondtheconventionallimitsinflowwhilststillmeetingtheimpactstandards,XANTARoffersoptimalpartperformance.FrontrunningLED-technologyismadepossibleusinggenericandspecialisedXANTARlightinggrades(Figure11,left).

Battery cases

Batterycasesareusuallymadeofplastics.Incontrasttocarbatteries,high-endbatteryboxesareproducedinPC/ABS(Figure10).Theiressentialfunctionistobeemergencypowersupplyunitsforhospitals,trainsorinmilitaryaircraft,highreliabilityisrequiredinmostdemandingcircumstances.ImportantreasonsforchoosingFRXANTARCarehightemperatureresistance,goodprocessingcharacteristicsandacombinationofexcellentflameretardantperformancewith‘WEEE’compliance.

Figure 10. High reliability battery cases, XANTAR C MC 3433.

Figure 11. Top, right: Outdoor luminaries made from XANTAR

G2F 23 R and XANTAR 19 UR. Bottom, right: Fluorescent tube

transparent cover, XANTAR MX 2034. Left: Front-running

LED-technology is made possible using generic and specialised

XANTAR lighting grades.

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Automotive applications

XANTARPolycarbonate&Blendsautomotiveapplicationsarepredominantlyfoundincarinteriors.Speciallydevelopedgradesoffersolutionsfordemandingapplicationssuchasforinstanceairconditioningandventingnozzles(Figure12,top),steeringcolumncladdings(Figure12,bottom),dashboardcomponentsandinteriorlighting.

XANTARbasedmaterialspasstoday’sverystringentenvironmentalrequirementswithrespecttoabsenceofheavymetalsandundesiredvolatilecomponents.Theythereforematchdemandsforfogging,emissionofvolatilesandodourinthecarinterior.WithXANTARE,ablendofPolycarbonateandPolyester,theseverestimpactrequirementscanbemet.XANTARC,ablendofPCandABS,isavailableinseveralcompositionstomatchtheapplicationsdemandsforheatresistanceandimpact.XANTARmaterialsofferexcellentsurfacefinish–buttheycanbepaintedifdesired.

Figure 12. Top: air ducts, XANTAR C CM 406.

Bottom: steering column cladding, XANTAR E EM 605.

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General Industry applications

Thankstoitsversatility,XANTARPolycarbonateisabletoofferuniquesolutionsinthegeneralindustriesmarket.Examplescanbefoundinthebuildingindustry,withapplicationssuchaswindowspacerprofiles(figure13,top),cableductingsystemsor(twinwall)sheetforconstructionpanels.XANTARPolycarbonate’seasyprocessingincombinationwithtransparency,purityandintrinsicflameretardancyaswellasUVstabilitymakesitthematerialofchoice.XANTARPolycarbonateisalsoagoodchoiceforapplicationsinthefood(packaging)andtoyindustries.GradesthatmeetbothFDA-andEC-legislationareavailableinamultitudeofviscositiesandcanbecustomcoloured(Figure13,bottom).Wheredesignofthepartisdelicateorcomplex,theexcellentdemouldingpropertiesofXANTARpolycarbonatefacilitatesecureanduninterruptedproductionprocesses.

Figure 13. Top: window spacer profiles, XANTAR 27 UR.

Bottom: food approved closures, XANTAR RX 2050 FD.

Extruded applications

Theextrusionshapingprocessimposesrigorousdemandsonprocessingperformance.Withouttherightperformance,afaultlessproductionprocesscannotbeachieved.ThecompoundingprocessofXANTARPolycarbonateistunedtomeetalltherelevantdemands.Apartfromtheuseofhighpurityresintostartwith,XANTARproductionischaracterisedbyspikingtoensuremidspecificationproductionrunsandabatchhomogenizationtreatment.Thecombinationofthesetwoprocessesensuresbatch-to-batchconsistencyeverytime.

Colourandimpuritiesarecontrolledbothvisuallyanddigitallytoensureourcustomers’flawlessproductionofopticalqualitylargepanelsheets.XANTARextrusiongradesareavailableintransparent,translucentandopaquecolours(Figure13,top).Onrequest,UV-resistantgradescanbeproduced.Alternatively,aspeciallytailoredmaterialisavailablefortheproductionofhighUV-resistantcaplayers,whichcanbeusedincombinationwithaco-extrusionlinetofurtherreducesystemcosts.

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Typical properties of XANTAR®

XANTAR® Polycarbonate

MitsubishiEngineeringPlastics’XANTARPolycarbonateisaversatilethermoplasticresinthatissuitableforawiderangeofapplicationsandcanbeconvertedusingallcommonmelt-processingtechniques.TheXANTARproductlineconsistsofgeneralpurposeandspecialgrades.

General purpose grades

TheseXANTARgradesareavailableinarangeofmeltviscosities,fromextremelylowtoveryhigh,andwithseveraladditivepackages(basicstabilized,steamresistant,mouldrelease,UVstabilized).Ageneralruleforpolycarbonateisthatthehigherthemeltviscosityofagrade,thebetterits(long-term)performance.WhenselectingthebestsuitableXANTARgrade,itisimportanttofindtheoptimumbalancebetweenprocessingcharacteristics(easeofprocessing,meltflowability)andperformance(mechanicalintegrityandlongtermstability).

GeneralpurposeXANTARgradesareself-extinguishingandareratedUL94V-2downto0.75mm;forsomespecialcasesevendownto0.4mm.XANTARgradesarealsoavailableinversionsapprovedforfoodcontact.

XANTARgeneralpurposegradesarecharacterisedby:- Crystalcleartransparency- Highimpactstrength- Excellenttemperatureresistance- Gooddimensionalstability- Biologicalinertness

Flame retardant (FR) grades

Theself-extinguishingcharacteristicsofXANTARcanbefurtherenhancedthroughtheuseofvariousflameretardant(FR)additivepackages,noneofwhichcontainchlorineorbromine.TherearetwomainXANTARFRgraderanges:- TransparentoropaquegradeswithaUL94V-0at

3mmrating(Fseriese.g.XANTARF23R)- OpaquegradeshavingaUL94V-0at1.5mm

rating(FCseriese.g.XANTARFC23R)

Inaddition,anumberofspecialgradesareavailable,forinstance:

- Specialgradesmeetingmoredemandingglowwireignition(GWI)requirements,forinstanceaccordingtoEDFspecifications.

- Specialgradeswithlowsmokedensityandlowsmoketoxicity,forinstanceaccordingtoNFF16-101/102,DIN5510-2andEN45545-2.

Glass fibre reinforced grades

Theadditionofglassfibresleadstoincreasedstiffnessandimproveddimensionalstability,whilenormallyductilityisdecreased.Glassfibrereinforcementisoftencombinedwithextraflame-retardancy.Reinforcementlevelsofbetween10%and40%glassfibresareoffered,whereasgradeswith20%reinforcementareavailableinvariousmeltviscosities.

XANTARG2F23R(with10%glassfibres)exhibitsanexceptionalductility(elongationatbreak>15%)eventhoughitisreinforced.

Engineering structural foam grades

TheXANTARSF22seriesisoptimizedforstructuralfoamapplications.Togetherwithablowingagentmasterbatch,itofferssuperiorimpactresistancecombinedwithaUL94V-0/5VAratingat4.8mm.Structuralfoamgradesareavailablewith5,20and30%glassfibrereinforcement.Forconvenientandreliableprocessing,itishighlyrecommendedtouseXANTARMX1051,blowingagentmasterbatch(exothermicchemicalblowingagentwithpolycarbonatecarrier).

Stress crack resistance modified grade

Incertaincircumstances,brittlefailurecanoccurinarticlesmadefromunmodifiedpolycarbonate.Examplesare:failureduetothepresenceofnotchesand/orthecombinationofchemicals(e.g.gasoline)withstresses.ModifiedXANTARgradesareavailablewithimprovedstresscrackbehaviourforthose‘impactdangerzone’situations.

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High-flow flame retardant grades

TheXANTARMX1000seriesistailoredfortherequirementsofofficeequipment(e.g.computerandmonitorhousings)andotherelectricandelectronicsapplications(chargers,junctionboxes,cartridges,etc).Besideshighflow,goodimpact,UL94V-0at1.5mmflammability,andexcellentcolourstability,thesegradesalsomeetrequirementssuchastheglow-wiretestat960°Cat1.5mmandtheballpressuretestat125°C.

Tailor-made grades

AlthoughtheXANTARportfoliocoversaverywiderangeofapplications,specificrequirements(e.g.specialflameretardancyregulations,extremetemperatures)orprocessingtechniques(e.g.blowmoulding,extrusionorrotationalmoulding)canrequirefine-tuningoradaptationofagrade.Thishasresultedinaseriesofspecialtailor-madeXANTARgrades.Forexample,forextrusionapplications,optimisedgradesareavailableforsolidsheet,twinwallsheetandUVcaplayerco-extrusion.Otherspecialextrusiongradesaresuitableforapplicationswheresevereflameretardancyrequirementshavetobemet.

Besideshighflow,goodimpact,UL94V-0at1.5mmflammability,andexcellentcolourstability,thesegradesalsomeetrequirementssuchastheglow-wiretestat960°Cat1.5mmandtheballpressuretestat125°C.

XANTAR® C, Blend of PC and ABS

BlendingofXANTARpolycarbonatewithABShasavarietyofeffectsonthepropertiesoftheblend,resultinginanewclassofmaterials.Forsomeproperties,suchastemperatureresistance,theblendperformanceisinbetweenthoseofthetwoparentmaterials.Specificadvantagesofthesematerialsareduetosynergeticeffects,suchaslowermeltviscosityandhigherimpactresistanceunderunfavourableconditions(lowtemperatures,sharpnotches,exposuretochemicalsorappliedstresses).

XANTARCincorporatesspeciallydevelopedhighpurityABSandoffersanimprovedpropertyprofilecomparedtootherPC/ABSblends.KeyXANTARCpropertiesare:

- highestflowincombinationwithexcellenttoughness

- highlevelofpurity- highstability- brightnaturalcolour

Thebenefitsare:easierfillingofcomplexparts,lowermoulddepositduringinjectionmoulding,lowvolatileslevelandreducedfoggingtendency,betterlong-termpropertyretentionandimprovedcolourconsistencyandappearance.XANTARCdeliversvaluethroughbroadeningthedesignandapplicationscope.

TheXANTARCproductlineconsistsofstandard,flameretardantandspecialgrades.

Standard grades

XANTARCgradesarebasedontheexcellentresinqualitiesofXANTARpolycarbonateandoptimisedABSgradesandareproducedbystate-of-the-artcompoundingtechnology.

XANTARCshowsanexcellentpropertybalancewhereextremelyhighflowiscombinedwithveryhighimpact,heatresistanceandlongtermperformance;allfeatureswhichaidinthemanufacturingofthinwalledparts(e.g.mobilephonehousings).IncomparisonwithotherPC/ABSblends,XANTARCexcelsinprocessabilitywithsignificantlyreducedmoulddepositduringinjectionmoulding,enablinglongeruninterruptedprocessing,consistentqualityandanimproved,smootherpartsurface.ComparedtotheyellowishnaturaltintofconventionalPC/ABSblends,XANTARCprovidesanintrinsicallybrightwhitenaturalcolour(Figure14).

16

Moreover,partappearance(glossandsurfacequality)islesssensitivetoprocessconditionsandmorestableduringlongtermageing.

Figure 14. In contrast to standard PC/ABS (left), XANTAR C

shows a bright white natural colour (right).

Flame retardant (FR) grades

XANTARCflameretardant(FR)gradesarebasedonalowvolatileflameretardant,thatis100%chlorinefreeandbrominefree.DuetothelowplasticizingeffectoftheflameretardanttheVicatsofteningtemperaturesofFRXANTARCgradesare10-15°ChighercomparedtoconventionalFRPC/ABSgrades.Thestronglyreducedvolatilityoftheflameretardantminimisesjuicing,outgassingandpollutionofprocessingequipment.AllgradespassUL94V-0ratingat1.5mm,andinadditionexhibit5V-ratings.LikeallXANTARCgrades,theFRXANTARCgradesshowveryhighflow,arecleanandbrightlycolouredandhaveimprovedstability.

Forapplicationsrequiringhighflow,XANTARCCF107isrecommended.Ifthereisaneedforincreasedheatdistortiontemperaturesormorerobustmechanicalperformance,XANTARCCF407canbeused.BothXANTARCCF107andCF407complywith‘BlueAngel’and‘WEEE’directives.

Tailor-made grades

Tomeetspecificrequirementsorprocessingtechniquesaseriesofspecialtailor-madeXANTARCgradesisoffered.Theseinclude:FRgrades,glassfibrereinforcedgrades(alsoincombinationwithflameretardant),extrusiongrades,andothers.

Someexamplesare:

- XANTAR C CE 407 / MC 3435/ MC 3437 for extrusion (PVC replacement) TheseXANTARCgradesareflameretardantPC/ABSwithoptimisedmeltviscosityforextrusion,ratedUL94V-0at1.5mm,andforinstancecomplyingwith‘BlueAngel’andDINVDE472,part815.

- XANTAR C MC 3433 for high-end enclosures, such as battery boxes and advanced metering equipment XANTARCMC3433isa(chlorine-andbrominefree)flameretardantPC/ABSmeetingUL94V-0at1.5mmwithoptimizedenvironmentalstresscrackresistance,mechanicalperformanceandgoodflowability.

- XANTAR C CF 447 for structural partsXANTARCCF447isa20%glassfibrereinforcedand(chlorine-freeandbrominefree)flameretardantPC/ABSgrade,ideallysuitedtostructuralpartsforofficeequipmentsuchasprinterguidingsystems.Itoffershighdimensionalstability,stiffnessandflameretardancy.

- XANTAR C MC 3700 for high aesthetics XANTARCMC3700isaPC/ABSgradewiththehighestqualitysurfaceappearanceandlowweld-linevisibility,offeringclearbenefitsin‘eye-catching’applications.

17

XANTAR® E, Blend of PC and Polyester

XANTAREisablendofXANTARpolycarbonate(PC)andpolyethyleneterephthalate(PET)orpolybutyleneterephthalate(PBT).Theseproductsaremainlydevelopedfortheautomotiveindustry,bothinteriorandexteriorapplicationsandconsistofstandardandspecialgrades.SpecialadditiveandcompoundingtechnologyresultsinapropertyprofileforXANTARE,whichisuniquecomparedtootherblendsofpolycarbonateandpolyester.

Itexhibitshighageingresistanceandhasbenefitsindemandingimpactsituationse.g.thecombinationoflowtemperatureperformanceandweldlines.Italsodisplayslowvolatilityduringprocessing(lowodour)andend-use(reducedwindshieldfogging).Duetoitsexcellentcompatibilitywithotherpolyestercomponentsitcaneasilyberecycledwithoptimalretentionofproperties(e.g.recyclingincombinationwithpolyestertextilecladdings).

XANTAR®, XANTAR® C and XANTAR® E

Colours

Adedicatedapproachtocolourdevelopment,includingsophisticatedcompounding,hasresultedinafamilyofcarefullyselectedandtestedadditives,whichgiveenhancedcolourconsistencyduringprocessingandduringapplicationlife-time.Nocadmium-containingpigmentsareused.

Transparant,translucent(onlyXANTAR!)andopaquecolourscanbemadeaccordingtocustomerspecification.Thisspecificationcanbevisual,instrumentalorboth,dependingoncustomerrequirements.State-of-the-artcolourlabfacilitiesandexpertiseguaranteebothhighlyaccurateabsolutecolourmatchingtospecificationaswellasbatch-to-batchconsistency.

XANTARgradesshowexcellenttransmissionoveraverywidewavelengthrange,whichforinstancealsoenablesIRapplications.‘Fantasycolours’isafeatureofferedwithXANTARandXANTARCinwhichmetallicflakesareincorporatedintothematerial,givingtheplasticparta‘metallicpainted’appearance.Fantasycoloursreducepaintingcostsinapplicationssuchascellularphones,housingsanddesklamps.

Electrical properties

XANTAR,XANTARCandXANTAREgradeshaveintrinsicgoodandconstantelectricalpropertiesthankstolowwaterabsorptionandtheuseofhighpurityrawmaterials.

ElectricalpropertiesforXANTARandXANTARCgradesareprovidedintheULyellowcardfile.Thesepropertiesincludehotwireignition(HWI),highcurrentarcignition(HAI),highvoltagearctrackingrate(HVTR),highvoltagearcresistance(D495)andcomparativetrackingindex(CTI).

Typicalratingsare:- HWIClass2(specialflameretardantgrades

class0)- HAIClass0to1,dependingongrade- HVTRClass2to3forunreinforcedgrades,Class

0to1forglassfilledgrades- D495Class5to6- CTIClass2to3.

MoredetailedinformationonelectricalpropertiescanbefoundinTable3.

Guaranteedhighlyaccuratecolourmatchingtospecificationaswellasbatch-to-batchconsistency

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XANTAR grades

Description Grade designation Col Min UL94 RTI ºC1) H H H D C

thick- W A V 4 T

ness El WI WOI I1) I1) T 9 I1)

mm R1) 51)

Non-reinforced 19 R (f2) - 22 R (f2) All 0.4 V-2 130 130 130 2 0 2 5 2

18 XX(f1) - 24 XX(f1) All 0.75 V-2 130 130 130 2 0 2 5 2

25 XX(f1) - 27 XX(f1) All 1.5 V-2 130 130 130 2 0 2 5 2

F 22 YY(f1)- F 25 YY(f1) All 3.0 V-0 130 125 130 3 1 2 6 2

FC 19 YY(f1) - FC 22 YY(f1) All 1.5 V-0 130 125 130 2 0 3 6 2

FC 23 YY(f1) - FC 25 YY(f1) All 1.5 V-0, 5VA (3 mm) 130 125 130 2 0 3 6 2

Glass G2F 23 YY(f1) - G2F 25 YY(f1) All 1.5 V-0, 5VA (3 mm) 130 130 130 2 1 1 6 3

reinforced G4F 22 YY(f1) - G4F 25 YY(f1) All 1.2 V-0 130 130 130 2 1 1 6 3

G6F 23 YY(f1) All 1.5 V-0 130 130 130 2 1 0 5 3

G8F 23 YY(f1) All 1.5 V-0 130 130 130 2 0 1 5 3

Specialties MX 1000 All 1.5 V-0, 5VB (2 mm) 110 105 110 0 1 2 5 2

MX 1001 All 0.75 V-0 80 80 80 2 0 0 6 2

MX 1002 All 1.5 V-0, 5VB (2 mm) 110 105 110 0 1 2 5 2

MX 1004 GY/BK 1.5 V-0 80 80 80 1 0 2 7 0

RX 2121 WT 2.0 V-0 80 80 80

RX 2124 NC 2.0 V-0 80 80 80 2 2 2 7 3

Structural SF 22 All 4.8 V-0, 5VA 80 80 80 2 4 1 6 4

foam SF 2220 - SF 2230 All 4.8 V-0, 5VA 80 80 80

XANTAR XRM grades

Description Grade designation Col Min UL94 RTI ºC1) H H H D C

thick- W A V 4 T

ness El WI WOI I1) I1) T 9 I1)

mm R1) 51)

Glass RX 5010 All 3.0 V-0, V-1 (1.5 mm) 80 80 80 1 0 0 6 3

Reinforced

Table 3. Underwriters Laboratories yellow card file for XANTAR, XANTAR C, XANTAR XRM and XANTAR LDS

Chemical resistance

XANTAR,XANTARCandXANTAREgradesareresistantagainstmanysubstances,althoughsomechemicalagentsmayattackundercertaincircumstances.ThechemicalresistanceofXANTAR,XANTARCandXANTAREgradesnotonlydependsonthenatureofthesubstanceorchemicalitisexposedto,butalsoontheconcentration,thetemperature,theexposuretime,themolecularweightandthestress(whichcanbearesultofmouldingand/orexternalloading).Ingeneral,modifiedXANTARgradesandXANTARblendswillbelesssensitivetoenvironmentalstresscrackingcomparedtostandardXANTARgrades.Formostdemandingapplications,whereenvironmentalstresscrackingshouldbeaslowaspossibleatbothhigh

andsub-zerotemperatures,XANTARXRMgradesaredeveloped.

Table4givesageneraloverviewofthechemicalresistanceofXANTAR.Thisoverviewmerelygivesindicativeinformation.Inordertodeterminetheactualchemicalresistanceunderpracticalcircumstances,abasicandfasttestprocedureisavailableatourTechnicalCenterinGeleen,TheNetherlands.Thetestallowsustoeasilyestablishtheeffectofachemicalagentonaselectedgradeundercertaincombinationsoftime,temperatureandstress.Forhighestaccuracyitisrecommendedtodeterminetheperformanceunder‘reallife’conditions.

19

Detailedandup-to-dateUL-datacanbefoundontheinternetwebsiteofUnderwritersLaboratoriesInc.http://data.ul.com.

Alcohols: monohydric Good

polyhydric Good

Bases: concentrated Poor

diluted (1:1) Poor

Esters Poor

Fats, oils, and greases Fair

Hydrocarbons: aliphatic Poor-Fair

aromatic Poor

fully halogenated Fair-Good

partially halogenated Poor

Inorganic acids: concentrated Fair

diluted (1:1) Good

Ketones Poor

Organic acids: concentrated Fair

diluted (1:1) Good

Phenols Poor

Salt solutions: acid Good

basic Fair

neutral Excellent

Chemical Rating

Table 4. Indicative chemical resistance of XANTAR polycarbonate.

Excellent - Recommended; no adverse effects after extended exposure.

Good - Acceptable; minimal loss of mechanical properties after long periods of exposure.

Fair - Marginal acceptability; loss of mechanical properties with intermittent exposure.

Poor - Not recommended for use with polycarbonate resins.

XANTAR C grades

Description Grade designation Col Min UL94 RTI ºC1) H H H D C

thick- W A V 4 T

ness El WI WOI I1) I1) T 9 I1)

mm R1) 51)

General CM 206, CM 206 U All 1.5 HB 60 60 60 3 0 0 6 0

purpose CM 406, CM 406 U All 1.5 HB 60 60 60 3 0 0 7 2

CM 506, CM 506 U All 1.5 HB 60 60 60 3 0 0 7 2

Flame CF 107 All 1.5 V-0, 5VB (2 mm), 95 80 80 1 0 4 6 1

retardant 5VA (3 mm)

CF 407 All 1.5 V-0, 5VB (3 mm) 95 95 95 2 0 0 7 0

CE 407 All 1.5 V-0, 5VB (3 mm) 95 95 95 1 0 0 6 0

MC 3433 All 1.5 V-0 95 80 80 2 0 2 6 2

MC 3435 All 1.5 V-0, 5VB (3 mm) 95 95 95 3 2 2 7 0

XANTAR LDS grades

Description Grade designation Col Min UL94 RTI ºC H H H D C

thick- W A V 4 T

ness El WI WOI I I T 9 I

mm R 5

General LDS 3710 BK 1.6 HB 60 60 60

Purpose

Improved LDS 3720 BK 0.7 HB 60 60 60

ductility LDS 3722 GY 1.0 HB 60 60 60

Flame retardant LDS 3730 BK 1.0 HB 60 60 60

1) These data are for 3 mm thickness

20

Designing with XANTAR®

Oneofthemostcriticalstepsinthedesignofaplasticproductistheselectionofthematerial.Thecombinationoftransparency,highimpactresistance,intrinsicflameretardancy,hightemperatureresistanceandexcellentelectricalpropertiesareunitedinXANTARPolycarbonate.

Wheretransparencyisnotrequiredandalowertemperatureresistanceisacceptable,polycarbonateblendsareagoodchoice.

XANTARC(PC/ABSblends)offersimprovedflowandESCR(EnvironmentalStressCrackResistance).CombinedwiththeductilityofXANTARC,thismakesitanexcellentmaterialforInformation&CommunicationTechnology(ICT)andautomotiveinteriorparts.

XANTARE(PC/Polyesterblends)combinesoutstandingductilityatverylowtemperaturesandverylowemissionofvolatiles.Forthisreasonithasbeensuccessfullyusedinverycriticalautomotiveinteriorapplications.

Makingtherightchoicerequiresknowledgebeyondcomparingdatasheets.

Choosing the right XANTAR® grade

XANTARpolycarbonateisavailableingradesrangingfromanaveragemolecularweightbetween18000and27000.

Manyofthepropertiesthatarecommonlyusedtodescribeaplasticdonotvarywithmolecularweightinpolycarbonate.Thisappliestotensilemodulus,lighttransmittance,HDTorVicatetc.Infact,mostofthepropertiesquotedinbrochuresdonotchangewithvariationsinmolecularweight.However,someimportantpropertiesarelargelyinfluencedbymolecularweight.Viscosityisagoodexample:thehigherthemolecularweight,thehighertheviscosity(lessflow).Alsotheengineeringorlong-termperformanceofpolycarbonateimproveswithincreasedmolecularweight.Agradewithahighermolecularweighthasahighercriticalstrainandislessnotchsensitive.

Inotherwords:ahigh-molecularweightpolycarbonatehasmore‘body’thanalow-molecularweightgrade.

Selectingtherightproductdependsontheenvironmentaswellasthelong-termperformancerequirementsoftheapplication(seeTable5).

Alowmolecularweightproductwillprocessmoreeasilythanahighmolecularweightpolycarbonate.However,forinjectionmouldingapplications,selectthegradewiththehighestmolecularweightthatcanbeprocessedinthespecificmouldandmouldingequipment.Thiswillprovidethebestlongtermperformancealthoughthisstrategymayappeartoruncontrarytothephilosophyofselectingthematerialthatiseasiesttoprocess.

Extrusionapplicationsfollowthesamerule,althoughinextrusionprocessesthemeltstrengthdeterminesthematerial’sprocessibility.Ingeneral,thematerialwiththehighestviscosityistheoptimalgrade.

Long term properties Higher viscosity

Complex/long flow parts Lower viscosity

Cold temperature impact Higher viscosity

Higher critical strain Higher viscosity

Long term water/steam “SR” grades

UV exposure “UR” grades

Flame retardancy “F” or “FC” grades

Higher modulus Glass fibres

Requirement Recommendation

Table 5. Selecting the right XANTAR grade type.

21

Product design

Dimensions

Dimensionaltolerancesplayamajorroleindeterminingthecostanddifficultyinmakingapart.Thedesignengineershoulddeterminewhetherornottighttolerancesareinfactnecessaryandcanbejustified.Optimally,tolerancesshouldbetightenoughtoensuresatisfactorypartperformanceandlargeenoughtoavoidunnecessarytoolingandmanufacturingcosts.Atthesametime,theenvironmentinwhichthepartmustoperatewilloftenprecludetheacceptanceofclosetolerances.E.g.ifapartmustoperatethroughawiderangeoftemperatures,thedimensionalchangeresultingfromthistemperaturevariationmaybegreaterthanthatallowedbythesetolerances.

PartsmouldedfromunreinforcedXANTAR,XANTARCandXANTAREshrinkbetween0.005mmand0.007mmperlinearmm.BecauseoftheisotropicnatureofXANTAR,XANTARCandXANTARE,itispossibletoholdverytighttolerancesdependingonthepart,tooldesignandprocessingconditions.Itisalwaysbesttohaveasmuchtoleranceaspossiblewhilestillmaintainingpartfunctionality.

Surface appearance

XANTAR,XANTARCandXANTAREofferexcellentreproductionofthemouldsurface.Everythingbetweenhighglossandheavilytexturedsurfacescanbecreated.Glassreinforcedmaterialstendtobeabrasiveandcareshouldbetakentomaintainthemouldsurfacesothatpartappearancedoesnotvaryfromtheoriginalintent.Ejectorpinsandsecond-surfaceribsandbossescandetractfromtheaestheticsofthepartsoitisimportanttoavoidplacingtheseincriticalappearanceareas.

WhileXANTAR,XANTARCandXANTAREarecapableofgoodmouldsurfacereproduction,theyarehighlyreliantonpropermoulding.Therefore,itiscriticaltofollowtherecommendationsforprocessingpolycarbonateandpolycarbonateblendstoobtainthebestsurfaceappearance.

Wall thickness

Wallthicknessshouldbeequaltoorgreaterthantheminimumallowedbythefunctionalrequirementsofthepartandtheprocessingcapabilitiesofthematerial.Wallsthatarethickerthannecessaryadd

costbyincreasedmaterialusageandlongercycletimes.Additionally,thickerwallsmaycauseproblemssuchassinkmarks,internalvoids,andpoorsurfaceappearance.Inordertoachievegreaterstrengthandstiffnessinthepart,ribsandgussetscanbeused.Theuseofribsandgussets,generally,providesoptimalcostperformance.

Forsolidinjectionmoulding,partsmadeoutofXANTAR,XANTARCandXANTAREshouldnotexceed3mmto4mmnominalwallthickness.Wallsthickerthan3mmto4mmresultinincreasedcycletimes(duetolongerperiodsrequiredforcooling),raisethelikelihoodofvoids,andsignificantlydecreasethephysicalpropertiesofthepart.Wherewallthicknessexceeds4mm,foaminjectionmoulding(XANTARSF22-series)ispreferred.Theoptimalthicknessforfoamapplicationsisaround6mm.

CareshouldbetakenforthoseapplicationsthatrequireUL94listingsthatthethinnestsectionofthedesignstillcorrespondswiththelistedflammabilityontheUL94YellowCard.

Ribbing

Theadditionofribstothepartallowsforathinneroverallwallthickness.Byallowingthinnerwalls,ribbingalsoreducescycletimeandcrosssectionalareaversusthickwalledparts.Thisallowsmaterialusageandpartweightreductionwithoutsacrificingphysicalproperties.

Typicallyribsshouldbenomorethan60%oftheadjacentwallthicknessinordertopreventsinksontheoppositeside.Radiishouldbeincorporatedtopreventstressconcentrationatthejunctureofribsandadjacentwalls.

Corners & radii

Sharpcornersactasstressrisersandareamongthemajorcausesofpartfailure.Mostthermoplasticsareparticularlysensitivetothisphenomenon.Agoodruletofollowistoemployinsideradiiequaltoaminimumof60%oftheadjacentwallthickness.Additionally,externalcornersshouldmaintainaconstantwallthicknessaroundtheradiusoftheinternalcorner.Thisreducesvariationsinwallthicknessandhelpspreventwarpageandsinks.

22

Tool design

XANTAR,XANTARCandXANTAREhavebeensuccessfullymouldedinawidevarietyoftoolsusingconventionaltwo-plate,three-plate,andhotrunnersystems.Itisessentialthatgooddesignpracticesarefollowedinordertoproducehighqualityproduct.Thefollowingarerecommendationsfortooldesigndetails.

Gates & runners

Mostofthefamiliargatingsystemssuchasconventional,sub-surface,andfanworkwellwithXANTAR,XANTARCandXANTARE.Gatelocationandsizeshouldbeselectedwithcaretominimizeshear(especiallyimportantfortheblends),surfaceimperfections,andpartdistortion.Gatesshouldbelocatedsothatmaterialflowsfromthickertothinnerwallsectionsandarebalancedinalldirections,asmuchaspossible.Runnersshouldbesizedlargeenoughtoallowfreeflowofthematerialrequiredtofillthecavitieswithoutproducingunnecessaryrework.Radiishouldbeusedatallcorners,includinggates.Theuseofcoldslugwellswillassistinremovingcoldmaterialfromthemeltfrontandallowthedeliveryofhotmaterialtothecavities.

Hotrunnersystemscanbeofgreatbenefit.Theyreducerunnerscrapandproducelowermoulded-instressesinpartsbydeliveringuniformlyhotmaterialtothecavity.MostofthehotrunnersystemmanufacturersmakeproductswhichcanbeusedwithXANTAR,XANTARCandXANTARE.

Thekeycharacteristicstorememberwhenselectingasysteminclude:

- Runnersystemshouldbewellbalanced- Materialchannelsshouldbeopen,freeflowing,

anddevoidofareaswherematerialcanhangupanddegrade

- Theheatersshouldbesizedtoallowsufficientheattobedeliveredanywhereinthesystem

- Allareasshouldbeuniformlyandaccuratelyheated

- Eachbranchrunneranddropshouldhaveitsownindividualcontrol.

Venting

MediumtohighinjectionspeedsarerecommendedforXANTAR,XANTARCandXANTARE,thereforeventingisparticularlyimportant.Ventsshouldbelocatedattheendoffillandanyotherlocationwheremeltfrontknittingandresultantgasentrapmentcanoccur.DimensionsofventingcanbereadfromFigure15.

Thedimensionsarechoseninsuchawaythataircanescapewithoutflash.Whenventscannotbeplacedonthepartingline,theyshouldbelocatedonejectorpins.Ventslocatedonstaticpins,suchascorepins,shouldnotbeusedastheywillbecomecloggedveryquicklyunlesstheyareconnectedtoavacuumsystemtokeepthemcleanandopen.

Figure 15. Construction of a venting channel for XANTAR

Polycarbonate & Blends.

23

Secondary operations

Machining

StandardmachiningtoolsworkwellforcuttingXANTAR,XANTARCandXANTAREandgenerallyprovidealongservicelife.Eitherhigh-speedsteelorcarbidetoolingcanbeused.Ifextensivemachiningisnecessary,youareadvisedtousetoolsthathaveoptimumgeometryasdefinedbyTheSocietyofthePlasticsIndustrytoensuremaximumproductivityandbestsurfacefinish.

Welding

WeldingofXANTAR,XANTARCandXANTAREisbasedontheinterdiffusionofmoleculechains,whichneedselevatedtemperatureandtime.Pressureisrequiredforgoodmechanicalcontact;inadditionithelpstocleanweldsurfacesbyoutflowofimpurities.Avarietyofweldingtechniquesdoesexistofwhichvibration/spin,ultrasonicandhotplateweldingarethemostpopular.Nowadays,laserweldingisbecomingincreasinglypopular.XANTARPolycarbonateisexcellentforlaserweldingthankstoitshightransparencyatvisibletonearinfraredwavelengths.UsingforinstanceconventionalNd:YAGlasers,itispossibletosuccessfullyweldXANTARonpolyestersandcopolyesters.

Adhesive bonding

AdhesivebondingallowsgreatfreedomindesignbecauseitcanbeusedeffectivelytobondXANTARandXANTARCtoavarietyofmaterialincludingtoitself,otherplastics,metals,wood,glassandceramics.Adhesivebonding,however,isnotwithoutdraw-backs.Theprimaryconcernsareslowprocessingrates,limiteduseincertainenvironmentsanddifficultiesinapplyingtheadhesiveduringtheassemblyoperation.

AdhesivebondingwithXANTAR,XANTARCandXANTAREcanbesatisfactoryif:

- Theproperadhesive(anepoxy,polyurethaneorsilicone)isselectedfortheapplicationandenvironment

- Thejointdesignisadequateforthesizeandshapeoftheproduct

- Thejointsurfaceisnotsmooth.Thesurfacecanhavemoulded-intextureormattefinish,oritcanbetreatedinasecondaryroughingoperation

- Thejointsurfaceiscleanandfreeofforeignmaterials,suchasdirt,mouldreleasespray,water,oil,etc.

- Theadhesiveisproperlyappliedandcured

AdhesivesthatutilizecomponentsincompatiblewithXANTARPolycarbonateshouldbeavoided.

Solvent bonding

XANTAR,XANTARCandXANTAREarewellsuitedtosolventbondingbecauseoftheiramorphousnature.Themostcommonsolventismethylenechlorideora5%solutionofpolycarbonateinmethylenechloridewheresurfacesdonotmateperfectly.

Whensolventbonding,methylenechlorideisappliedtothejointareaofoneorbothcomponentsandthetwocomponentsarethenheldtogetherinafixtureunderapressureof1.5-4MPa.Thebondisthencuredtoformajointinonetofiveminutes,dependingonthesizeandshapeofthejointarea.

Environmentalconditions,suchaselevatedtemperatures,cancausestresscrazing.Therefore,thebondshouldbedriedfor24to48hoursatatemperaturejustbelowthemaximumanticipatedoperatingtemperature.Thisofteneliminatescrazing,whichcanbecausedbyentrappedsolvent.

Printing

XANTAR,XANTARCandXANTAREcanbeprintedusingvariousprocessesincludinghotstamping,padprinting,andsilkscreening.XANTAR,XANTARCandXANTAREmaybehotstampedusingstandardequipmentandfoils.Hotstampfoilscomeinawidevarietyofgradesofferingdifferenttextures,colours,andmechanicalandadhesiveproperties.ForthebestgradestobeusedincombinationwithXANTAR,XANTARCorXANTARE,consultthesupplierofthehotstampingfoil.

24

Laser marking

Laserprintingoffersspecificadvantages,impossibletomeetwithconventionalprintingsystems(environmentallyfriendlyandveryflexible).Severalsingle-colour,highcontrast,laserprintableXANTAR,XANTARCandXANTAREgradeshavebeendevelopedbythelaserexpertsattheTechnicalCenterinGeleen,TheNetherlands(Figure16).

Painting/coating

DuetothepolarityofXANTAR,XANTARCandXANTARE,paintingandcoatingcantakeplacewithoutanyproblems.However,sincebothmaterialsaresensitivetostresscrackingincontactwithcertainsolvents,itisstronglyadvisedtousepaintsorcoatingswhicharesuitableforpolycarbonate.

Metalising

XANTAR,XANTARCandXANTAREcanbereadilymetalisedbymostcommontechniques,e.g.vacuummetalising,cathodesputtering,flamespray,arcsprayandelectrolessplating.MetalisingcanbeappliedforvariousreasonssuchasEMIshielding,(light)reflectionandaesthetics.Highreflectivemetallayerscanbeobtainedwithuniformthicknesswhichshow,ingeneral,verygoodadhesivebondingtoXANTAR,XANTARCandXANTARE.For(mechanical)protection,themetallayercanbecoatedadditionally.Also,othermethodsformetalisingarepossible,e.g.applicationofaconductivecoatingorveryselectivelybyemployingtheinnovativeXANTARLDStechnology.

Figure 16. XANTAR, XANTAR C and XANTAR E grades can

readily be laser marked. Using special laser marking grades,

design freedom can be further enhanced.