Ultradur
®
Polybutylene terephthalate (PBT)
BASF Plastics
key to your success
Ultradur®
Ultradur® is BASF’s trade name for its line of partially crystalline saturated polyesters. This line is based
on polybutylene terephthalate and is employed in
applications demanding a high performance level
such as load bearing parts in different industrial
sectors. Ultradur® is outstanding for its high rigidity and strength, very good dimensional stability,
low water absorption and high resistance to many
chemicals. Moreover, Ultradur® exhibits exceptional
resistance to weathering and excellent heat aging
behavior.
2
ULTRADUR®, A HEAVY-DUTY MATERIAL…
… in automotive engineering
… in electrical engineering and electronics
… in precision and mechanical engineering
4
6
8
04 - 09
10
14
19
20
21
10 - 23
THE PROPERTIES OF ULTRADUR®
Product range
New in the product line: Ultradur® High Speed
Mechanical properties
Tribological properties
Thermal properties
Electrical properties
Fire behavior
Resistance to chemicals
Behavior on exposure to weather
23
THE PROCESSING OF ULTRADUR®
General notes
Injection molding
Extrusion
Fabrication and finishing processes
24
27
34
38
24 - 39
Safety notes
Delivery and storage
Ultradur® and the environment
Quality management certification
Ultradur® Nomenclature
Colors
Subject Index
The product range of BASF plastics at a glance
40
40 - 43
GENERAL INFORMATION
41
42
43
Ultradur® in automotive
engineering
Ultradur® demonstrates its strengths wherever highquality and above all heavy-duty parts are required –
for example in the automotive industry. Ultradur®
is rigid, impact-resistant, dimensionally stable, heat-
proof, weather-resistant and resistant to fuels and
lubricants. These properties have made Ultradur®
an indispensable ma­terial in many applications in
modern automotive ­engineering.
Headlamp
Ultradur® is employed in housings and functional parts in ­electric
drives, housings and mountings for various electrical and electronic
components, in windscreen wiper arms, door handles, headlamp
­structures, mirror systems, connectors, sun-roof components, in housings for locking systems and in many other applications.
4
Mirror acuator
housing
Sliding roof frame
Plug-in connector
Clip
5
Ult ra D UR ® , A H E A V Y -DUT Y M A T E RI A L…
Ultradur® in electrical engineering
and electronics
Parts which are becoming ever smaller and more
complex and offer steadily increasing functionality­
are typical of the high demands imposed on the
­materials used in electrical engineering and electronics. This is no problem for Ultradur®. It is rigid,
flame and heat resistant, it exhibits good dimensional stability and outstanding long-term electrical
and thermal performance.
Loose buffer tubes for optical fibers
Ultradur® is used in plug-in connectors, connector strips, switching
systems, housings for automatic cutouts, capacitor pots, in coil formers,
lamp parts, PC fans, power supply ­components, parts for electric drives,
sheathing for waveguides and many other products and not least in
vehicle electrical systems ( ignition coil housing).
Steering angle sensor
6
Circuit breaker
Mechatronic control unit
7
Ult ra D UR ® , A H E A V Y -DUT Y M A T E RI A L…
Ultradur® in precision and
mechanical engineering
Long service life, perfect operation and dimensional
accuracy are properties which turn a modern component into a first-class product.
Ultradur® contributes to this. It affords good surface quality and dimensional stability, high rigidity,
compressive strength and it has particularly low
warpage.
Bristles
Plug-in connector
Ultradur® is employed in functional parts for printers, copying equipment, cameras and optical devices, gas meter housings and housings
for valves, pumps and a wide variety of other applications.
8
Dial caliper
Shower head
Pump pressure housing
9
Ult ra D UR ® , A H E A V Y -DUT Y M A T E RI A L…
The properties of Ultradur®
The Ultradur® grades are polyalkylene terephthalate
molding compounds based on polybutylene terephthalate. The chemical structure is illustrated in the
following structural formula:
O
O
–C–O–CH 2–CH2–CH2–CH2–O
C–
Ultradur® is produced by poly­con­densation of terephthalic acid or dimethyl terephthalate with 1,4 butanediol using special catalysts. Terephthalic
acid, dimethyl terephthalate and 1,4 -butanediol are
obtained from petrochemical feedstocks, such as
xylene and acetylene.
n
Product range
New in the product line: Ultradur® High Speed –
more efficient with nanotechnology
The most important applications of Ultradur® are automotive
­engineering, electrical engineering, electronics and telecommunications
as well as precision engineering and general mechanical engineering.
The most varied products from the Ultradur® range are used for implementing these applications. When selecting the most suitable types for
your specific purpose our technical marketing will be glad to help.
10000
Viscosity [Pa· s]
B 4300 G6 Standard 255 °C
B 4300 G6 Standard 265 °C
B 4300 G6 Standard 275 °C
1000
100
10
B 4300 G6 High Speed 255 °C
B 4300 G6 High Speed 265 °C
B 4300 G6 High Speed 275 °C
1
10
100
1000
10000
100000
Shear rate [1/s]
Fig. 1: Under the same shear, Ultradur® High Speed exhibits a much
lower viscosity than standard PBT
10
New in the Ultradur® product line is the rheologically modified Ultradur®
High Speed, one of the first engineering plastics whose flowability was
markedly improved through the addition of nanoparticles. Ultradur®
High Speed – created primarily for injection molding – reduces the
injection pressures and cycle times, thus achieving considerable cost
benefits during processing.
Nanotechnology is the key
The key to this innovation lies in the admixture of an additive of finely
dispersed nanoparticles. They have made it possible to significantly
lower the melt viscosity of Ultradur® (Fig. 1). The particle size of the
additive ranges from 50 to 300 nanometers in the case of Ultradur®
High Speed. The structural viscosity remains constant while the melt
viscosity decreases by about 50 % in an Ultradur® containing 30 %
glass fibers. Therefore, depending on the fiberglass content, the new
Ultradur® High Speed flows at least twice as far as comparable standard PBT types. The mechanical properties regarding stiffness and
strength, shrinkage behavior and thermal stability under heat are not
affected by this modification.
A plus for processors
Owing to the lower melt viscosity, it is sufficient to use lower injection and holding pressures. During the injection-molding process, the
reduction in the melt temperature makes it possible to shorten the
cooling time and thus the total cycle time. The low-viscosity Ultradur®
High Speed can flow into even finer molds, so that it can be employed
to produce completely new components.
T H E PR O PE R T I E S OF Ult raDUR ®
A filling study (Fig. 2) shows that the very thin webs of the small plug
weighing just 1.5 grams are not filled with standard PBT (shown on the
left ) while they are filled very well with the easy flowing Ultradur® High
Speed (shown on the right). Even thin-walled components having a
greater content of reinforcement materials such as glass fibers or mineral fillers can be manufactured using the new easy-flow Ultradur® High
Speed. This translates into fundamentally better mechanical properties
along with thinner walls. The entire configuration of the machine can be
streamlined: smaller injection-molding units, molds with fewer injection
points, in other words, fewer expensive hot runner nozzles.
In comparison to conventional Ultradur®, up to 50 percent less masterbatch can be used with Ultradur® High Speed while still obtaining
the same color depth. The pigments are better dispersed and the color
distribution is more uniform. This effect can also be seen in terms of
the coating properties since a more homogeneous color impression is
achieved using the same amount of pigment. Moreover, lasers can be
used to write on all grades of Ultradur® High Speed that are dyed black.
Preferred applications: automotive electronics
Another advantage of Ultradur® High Speed comes to the fore in the
production of electronic components for cars. ABS housings, for
instance, are manufactured by overmolding metal circuit-board conductors with polymer. The higher the pressure acting on the circuit-board
conductors, the greater the risk that they will be bent or compressed,
thereby losing their functionality. Thanks to its improved flowability,
Ultradur® High Speed lowers the pressure that is exerted on the circuitboard conductors during the injection-molding process, reducing the
deformation of the circuit-board conductor (Fig. 3).
Easy to color
Uniformly distributed nanoparticles are also the reason why Ultradur®
High Speed can be homogeneously colored with less color batch. As
shown in Figure 4, homogeneous coloring can already be attained with
0.1 % of a masterbatch based on blue PE.
Fig. 3: The flowability of Ultradur® High Speed ( right ) is also advantageous for overmolded circuit-board conductors: the undesired misalignment is largely suppressed
Fig. 2: Whereas standard PBT ( left ) does not completely fill the component (arrow ), Ultradur® High Speed manages to completely fill the webs
Fig. 4: Comparison of the masterbatch distribution: left (0.1 % blue in
Standard PBT 30 % GF), right (0.1 % blue in B4300 G6 High Speed)
11
Better adhesion
The adhesion of Ultradur® High Speed to soft components as well as
to metal during chemical electroplating is considerably better than with
a standard PBT. The adhesion in N /mm is almost twice as high for the
material combination of Ultradur® High Speed and TPU than with conventional Ultradur® (Fig. 5).
Adhesion [N/mm]
The properties of Ultradur®
14
12
C 65 A 15HPM
C 85 A 15HPM
1,0
10
8
Economically and environmentally advantageous
The Swiss Federal University of Technology in Zurich, Switzerland ( ETH
Zürich) has quantified the economic as well as environmental advantages of this new material. Owing to the good flowability, the manufacture of injection-molded parts is not only cheaper but also helps to
save energy and to carefully treat the environment (Fig. 6).
0,8
6
4
2
0
0,5
1,0
B 4300 G6
Standard
1,5
B 4300 G6
High Speed
Molex connector
Environmental burden [standardized]
Fig. 5: Adhesion to TPU by standard PBT in comparison to Ultradur®
High Speed having hardness values of 65 Shore A and 85 Shore A
0.7
1.0
1.3
1.3
1.0
Standard PBT
0.7
Costs [standardized]
Ultradur ® High Speed
Fig. 6: Eco-efficiency analysis of Ultradur® High Speed in comparison
to standard PBT
12
T H E PR O PE R T I E S OF Ult raDUR ®
Table 1: The Ultradur® product range at a glance
Unreinforced
Injection grades
Extrusion grades
B 2550
easy-flow properties
B 2550
low-viscosity grade
B 4500
FDA compliant
B 4500
medium-viscosity extrusion grade
B 4520
standard grade, easy demolding
B 4520
B 6550 L
B 6550 LN
h igh-viscosity extrusion grade
high-viscosity extrusion grade
with optimized feeding behavior
Glass-fibre reinforced
Standard grade (PBT - GF )
B 4300
G2-G10 (10 - 50 % GF )
Balance between stiffness and toughness, easy to process
Low-warpage grades (PBT+ ASA - GF )
S 4090
G2-G6 (10 - 30 % GF )
GX-G6X (14 - 30 % GF)
PBT+ ASA blend with very low warpage, very good flow properties and low density
Grades for good surface finishes (PBT+ PET - GF )
B 4040
G4-G10 (20 - 50 % GF )
PBT+ PET blend for applications in which good surface appearance is essential
Flame-retardant grades (PBT - GF - FR)
B 4406
G4 / G6 (20 / 30 % GF )
Standard halogenated flame-retardant grade (UL 94 V-0 at 0.75 mm); low warpage
B 4400
G5 (25 % GF)
Flame-retardant grade (UL 94 V-0 at 1.5 mm) with very high CTR;
contains no halogen compounds, antimony or elementary phosphorus
Specialties
Impact modified products
B 4520
Z2
Unreinforced injection-molding grade with high impact strength,
even at low temperatures
B 4030
G6 (30 % GF )
Glass-fiber reinforced injection-molding grade with high impact strength
enhanced resistance to hydrolysis
Mineral reinforced grades
B 4300
M5 (25 % Mineral)
Mineral reinforced grades with low warpage; produces good surface finish
B 4300
GM 42 (20 % GF, 10 % Mineral )
Mineral- and glass-fiber reinforced grade with low warpage; produces good surface finish
B 4300
M2 (10 % Mineral )
Mineral reinforced grade with low warpage and high impact strength,
even at low temperatures Instrument panel
13
The properties of Ultradur®
Mechanical properties
The strength and rigidity of glass-fibre reinforced Ultradur® grades are
substantially higher than those of the unreinforced Ultradur® grades.
Figure 7 shows the dependence of the modulus of elasticity on the
glass fiber content.
Elongation [%]
The shear modulus and damping values (Figs. 8 and 9) measured in
torsion pendulum tests in accordance with ISO 6721-2 as a function of
temperature provide useful insight into the temperature-dependence of
the properties of the unreinforced and reinforced Ultradur® grades.
7
B 4520
>50
6
5
S 4090 G2
B 4300 G2 S 4090 G4
B 4040 G2 B 4300 G4
S 4090 G6
B 4040 G4 B 4300 G6
B 4040 G6 B 4040 G10
B 4300 G10
4
3
2
The behavior under short, uniaxial tensile loads is demonstrated by
stress-strain diagrams. Figure 13 shows the stress-strain diagram for
unreinforced Ultradur® B 4520 and Figure 14 shows that for glass-fibre
reinforced grades as a function of temperature. In the latter diagram
the effect of the increasing glass fibre content is apparent.
10000
5000
B 4520
1000
500
Shear modulus G
100
50
1.0
10
5
1
0.5
1
0
2,500
4,500
7,100
10,000
12,000
Modulus of elasticity [MPa]
Fig. 7: Modulus of elasticity and elongation
14
The good strength characteristics of the unreinforced and glass-fibre
reinforced Ultradur® grades permit high mechanical loads even at
­elevated temperatures (Figs. 10 -12).
Logarithmic decrement [�]
Unreinforced Ultradur® is distinguished by a balanced combination of
rigidity and strength with good impact-resistance, thermostability and
sliding friction properties and excellent dimensional stability.
The pronounced maximum in the logarithmic decrement at + 50 °C
identifies the softening range of the amorphous fractions while the
crystalline fractions soften only above + 220 °C and thus ensure
dimensional stability and strength over a wide range of temperature.
Shear modulus [MPa]
The Ultradur® product range includes grades with the most varied
mechanical properties such as rigidity, strength and impact-resistance.
0
-100
log. decrement �
-50
0
50
100
150
200
0.5
0
Temperature [°C]
Fig. 8: Shear modulus and logarithmic decrement of unreinforced
Ultradur® as a function of temperature ( in accordance with ISO 6721-2 )
T H E PR O PE R T I E S OF Ult raDUR ®
10
1.0
Shear modulus G
1000
B 4300 G4
S 4090 G4
500
log. decrement �
Tensile strength [MPa]
Logarithmic decrement [�]
Shear modulus [MPa]
100
50
5000
200
180
160
140
120
B 4300 G6
B 4300 G4
B 4300 G2
100
80
60
B 4300 G4
S 4090 G4
0.5
40
20
0
-100
-50
0
100
50
150
200
0
0
-40 -20 0
23
50
Temperature [°C]
100
150
Fig. 9: Shear modulus and logarithmic decrement of glass-fiber
reinforced Ultradur ® as a function of temperature ( in accordance
with ISO 6721-2)
Fig. 11: Tensile strength of glass-fiber reinforced Ultradur® B as a
function of temperature (in accordance with ISO 527, take-off speed
5 mm /min)
Yield stress [MPa]
Tensile strength [MPa]
Temperature [°C]
120
100
80
B 4520
60
200
180
160
140
120
S 4090 G6
S 4090 G4
S 4090 G2
100
80
40
60
40
20
20
0 -40
-20
0
23
50
100
Temperature [°C]
Fig. 10: Yield stress of unreinforced Ultradur® as a function of
temperature (in accordance with ISO 527, take-off speed: 50 mm /min)
0
-40 -20 0
23
50
100
150
Temperature [°C]
Fig. 12: Tensile strength of glass-fiber reinforced Ultradur® S as a
function of temperature (in accordance with ISO 527, take-off speed
5 mm /min)
15
Toughness, impact strength and
low-temperature impact resistance
Impact strength may simply be specified, for example from the stressstrain diagram, as the deformation energy at failure (see Figs. 13
and 14).
A further criterion for toughness is the impact resistance of unnotched
test rods in accordance with ISO 179/1eU. According to Table 2 the
impact resistance of unreinforced Ultradur® B4520 is ­higher than that
of glass-fibre reinforced Ultradur® grades.
Comparative values closer to practical conditions for the impact properties of the materials under impact loads can be measured by impact
tests or falling weight tests in accordance with DIN 53443. Based
on this standard the 50 % impact-failure energy ( E 50), i. e. the falling
energy at which 50 % of the parts are damaged, was determined for
test boxes having a wall thickness of 1.5 mm (see Table 2 ). The failure
energy is dependent on the dimensions, the thickness of the walls, the
reinforcement of the moldings and on the processing conditions.
Tensile stress [MPa]
The properties of Ultradur®
B 4520
100
80
-40°C
60
-20°C
0°C
23°C
30°C
40
40°C
50°C
60°C
20
0
2
4
80°C
100°C
120°C
140°C 160°C
6
8
10
Elongation [%]
Fig. 13: Stress-strain diagrams for unreinforced Ultradur® at different
temperatures (in accordance with ISO 527, take-off speed 50 mm /min)
If the highest possible notched or low-temperature impact strengths
are required impact-modified grades must be employed. In this case the
best low-temperature toughness is achieved by Ultradur® B 4520 Z2.
Behavior under long-term static loading
The loading of a material under a static load for relatively long periods
is marked by a constant stress or strain. The tensile creep test in
accordance with DIN 53444 and the stress relaxation test in accordance with DIN 53441 provide information about extension, mechanical strength and stress relaxation behavior under sustained loading.
The results are illustrated as creep modulus plots, creep curves and
isochronous stress-strain curves (Figs. 15 and 16 ). The graphs reproduced here are just a selection from our extensive plastics databases
which we will be happy to place at your disposal on request.
Table 2: Dependence of impact strength (ISO 179 /1eU) and impact failure energy (E 50) (DIN 53443) on the glass fiber content
16
Property
Glass content
Unit
Wt.-%
B 4520
B 4300 G2
B 4300 G4
B 4300 G6
B 4300 G10
0
10
20
30
50
Impact-failure energy (E 50)
J
> 140
12
5
1.6
0.8
Impact strength + 23 °C
kJ / m
290
40
58
67
55
2
T H E PR O PE R T I E S OF Ult raDUR ®
Stress [MPa]
200
B 4300 G2
B 4300 G4
-40°C
160
-20°C
-20°C
140
-40°C
-20°C
0°C
120
100
0°C
23°C
0°C
23°C
40°C
40°C
23°C
80
60°C
80°C
100°C
120°C
140°C
60°C
80°C
100°C
120°C
140°C
40°C 80°C
60°C 100°C
120°C
60
B 4300 G6
-40°C
180
40
140°C
20
0
2
4
6
8
10
0
2
4
6
8
10
0
2
4
6
8
10
Elongation [%]
Tensile stress [MPa]
Fig. 14: Stress-strain diagrams for glass-fiber reinforced Ultradur® at different temperatures ( in accordance with ISO 527, take-off speed 5 mm /min)
NK 23/50
1h
10 h
100 h
1000 h
10000 h
40
30
60 °C
20
100 °C
1h
10 h
100 h
1000 h
1h
10 h
100 h
1000 h
10
0
5
10
15
Elongation [%]
Fig. 15: Isochronous stress-strain curves for Ultradur® B 4520 under normal conditions in accordance with DIN 50014-23/50-2 and
at 60 °C and 100 °C ( DIN 53444)
17
Tensile stress [MPa]
The properties of Ultradur®
100
1 h 10 h
NK 23/50
80
60
100
100 h
1000 h
40
20
20
0
0
100
100°C
80
140°C
80
60
1 h 10 h
40
1000 h
20
0
1 h 10 h 100 h
1000 h
60
10000 h
40
100
60°C
80
1
60
2
1h 10 h 100 h
1000 h
40
100 h
20
0
3
1
2
3
Elongation [%]
It can be gathered from the illustration that in the case of Ultradur the
stress remains practically constant above about 107 load cycles.
120
Test shape UB
Test shape WB
Dimensions in mm
40
80
18
6
60
10
30
30
UB
WB
40
UB Load-cycle frequency: 1500 rpm
WB Load-cycle frequency: 900 Hz
®
When applying the test results in practice it has to be taken into
account that at high load alternation frequencies the workpieces may
heat up considerably due to internal friction. In such cases, just as at
higher operating temperatures, lower flexural fatigue strength values
have to be expected.
16
18
15
10
8
100
30
Behavior under cyclic loads, flexural fatigue strength
Engineering parts are frequently subjected to stress by dynamic forces,
especially alternating or cyclic loads, which act periodically in the same
manner on the structural part. The behavior of a material under such
loads is determined in long-term flexural fatigue tests or in rotating
bend­ing fatigue tests (DIN 53442) up to very high load-cycle rates.
The results are presented in Wöhler diagrams obtained by plotting the
applied stress against the load-cycle rate achieved in each case (see
Fig. 17 ). The flexural fatigue strength is defined as the stress level a
sample can withstand for at least 10 million cycles.
Stress amplitude [MPa]
Fig. 16: Isochronous stress-strain curves for Ultradur® B 4300 G6 under normal conditions in accordance with DIN 50014-23/50-2 and at 60 °C,
100 °C and 140 °C in accordance with DIN 53442 (60 °C /6 % r. h.; 100 °C und 140 °C < 1 % r. h.)
20
0
10 4
10 5
10 6
10 7
10 8
Load-cycle rate
Fig. 17: Flexural fatigue strength of Ultradur® B 4300 G6 under normal
conditions as defined by DIN 50014-23 / 50-2 in accordance with
DIN 53442, injection-molded test specimen
T H E PR O PE R T I E S OF Ult raDUR ®
Tribological properties
Ultradur® is suitable as a material for sliding elements due to its excellent sliding properties and very high resistance to wear.
Sliding properties are very highly dependent on the system as a result
of which reliable prediction of the behavior of the paired material is difficult. Figures 18 and 19 show examples of friction values and wear
rates for unreinforced and glass-fiber reinforced Ultradur® on a special
tribological system having two different depths of roughness.
0.70
S 4090 G6
0.60
0.50
S 4090 G4
0.40
B 4300 G6
0.30
B 4520
0.20
0.70
0.60
B 4300 G6
0.50
S 4090 G6
0.40
0.30
S 4090 G4
B 4520
0.20
0.10
0.10
0.00
Mirror actuator
housing
Coefficient of sliding friction [µ]
Coefficient of sliding friction [µ]
The coefficient of sliding friction and the wear rate due to sliding friction depend on the contact pressure, the temperature of the sliding
surfaces and the sliding distance covered. The surface roughness and
the hardness of the paired material is decisive. The sliding speed has
no appreciable effect if heating and modification of the sliding surfaces
are avoided.
0
1
2
3
4
5
6
7
8
9
10 11 12
Wear rate due to sliding friction WI/s [µm/km]
Fig. 18: Coefficient of sliding friction and wear rates of unlubricated
Ultradur® at 0.15 µm depth of roughness; tribological system:
pin-on-disk; base material: disk of 100 Cr 6/800 HV steel; opposing­
material: plastic; ambient temperature: 23 °C; contact pressure:
1 MPa; sliding speed: 0.5 m /s
0.00
0
1
2
3
4
5
6
7
8
9 10 11 12
Wear rate due to sliding friction WI/s [µm/km]
Fig. 19: Coefficient of sliding friction and wear rates of unlubricated
Ultradur® at 3 µm depth of roughness; tribological system: pin-on-disk;
base material: disk of 100 Cr 6/800 HV steel; opposing material:
plastic; ambient temperature: 23 °C; contact pressure: 1 MPa;
sliding speed: 0.5 m /s
19
The properties of Ultradur®
Thermal properties
As a partially crystalline plastic, Ultradur® has a narrow melting range
between 220 °C and 225 °C. The high crystalline component makes it
possible for stress-free Ultradur® moldings to be heated for short periods
to just below the melting temperature without undergoing deformation or
degradation.
Ultradur® is distinguished by a low coefficient of linear expansion. The
reinforced grades in particular exhibit high dimensional stability when
temperature changes occur. In the case of the glass-fiber reinforced
grades, however, the linear expansion is determined by the orientation
of the fibers.
The presence of glass fibers reinforcement the dimensional stability on
exposure to heat ( ISO 75 ) increases significantly by comparison with
unreinforced grades.
Behavior on brief exposure to heat
Apart from the product-specific thermal properties the behavior of
Ultradur® components on exposure to heat also depends on the
­duration and mode of application of heat and on the loading. The
shape of the parts is also important. Accordingly, the dimensional
­stability of Ultradur® parts cannot be estimated simply on the basis
of the temperature values from the various standardized tests.
The shear modulus and damping values measured as a function of
temperature in torsion pendulum tests in accordance with ISO6721-2
afford valuable insight into the temperature behavior. A comparison of
shear modulus curves (see Figs. 8, 9 and 14) gives ­provides information about the different thermomechanical effects at low deformation
stresses and speeds. Based on practical experience the therm in the
torsion tests in which the start of softening becomes apparent.
Moving platen
(wiper engine housing)
20
Heat aging resistance
Thermal aging is the continuous, irreversible change (degradation) of
properties under the action of elevated temperatures.
The determination of the aging characteristics of finished parts under
operational conditions is often difficult to carry out because of the long
service life required.
The test methods developed for thermal aging using standardized test
specimens make use of the increasing reaction rate of chemical pro­
cesses at higher temperatures. This dependence of service life on
temperature described mathematically by the Arrhenius equation is the
basis of the international standards IEC 216, ISO 2578 and the US
standard UL 746B.
The temperature index ( TI ) is defined as the temperature in °C at which
the permitted limiting value (usually decline of the property to 50 % of
the initial value) is reached after a defined time usually 20,000 hours.
The temperature index is available for many products and various
properties (e. g. tensile strength). The temperature indices are given in
the Ultradur® product range. If required we can provide the data and
also the associated calculation program on data media.
In Figure 20 the tensile strength of Ultradur® B 4300 G6 is plotted as
a function of storage time and storage temperature. From the graph a
temperature-time limit in accordance with IEC 216 of approx. 140 °C
after 20,000 hours can be extrapolated on the basis of a 50 % decline
in tensile strength.
Ultradur® moldings become only slightly discolored on long exposure
to thermal stress in the aforementioned temperature-time limits. In
the case of uncolored Ultradur® B 4520 for example, only a very slight
change in color can be observed after exposure to a temperature of
110 °C for 150 days. Even after storage for 100 days at 140 °C discoloration due to oxidation is slight, i. e. the material is suitable for
inspection windows exposed to high temperatures, e. g. in the domestic
appliance sector.
T H E PR O PE R T I E S OF Ult raDUR ®
Airbag connector
Motor circuit breakers
Fire behavior
Ultradur® is of great importance in electrical engineering and electronics. It is used in insulating parts, such as plug boards, contact strips
and plug connections for example, due to its balanced range of properties. These include good insulation properties (contact and surface
resistance) in association with high dielectric strength and good tracking current resistance together with satisfactory behavior on exposure
to heat, in aging, and the possibility of meeting the requirements for
increased fire safety by incorporation of fire protection additives. Electrical test values are compiled in the Ultradur® product range.
General notes
Above 290 °C Ultradur® grades slowly begin to decompose. In doing
so flammable gases are given off which continue to burn after ignition. These processes are affected by many factors so that, as with
all flammable solid materials, no definite flash point can be specified.
The decomposition products from charring and combustion are mainly
carbon dioxide and water and depending on the supply of oxygen
small amounts of carbon monoxide, tetrahydrofuran, terephthalic acid,
acetaldehyde and soot. The decomposition products formed in the
temperature range up to 400 °C have been shown in toxicological
investigations to be less toxic than those produced under the same
conditions from wood. At higher temperatures they are equally toxic.
The calorific value Hu according to DIN 51900 is about 31,000 kJ/kg
(unreinforced grades).
Dielectric constant �r
Time [h]
Figure 21 shows the dielectric constant and the dissipation factor as
a function of frequency with reference to the example of Ultradur® S
4090 G4. The electrical properties are not affected by the moisture
content of the air.
10 5
5.0
0.03
S 4090 G4
4.0
0.02
Dissipation factor �
Electrical properties
�r
B 4300 G6
10 4
3.0
10 3
135 140 145 150 155 160 165 170 175 180
Temperature [°C]
Fig. 20: Thermal endurance graph for glass-fiber reinforced Ultradur®
( IEC 216-1)
tan �
0
10 1 10 2 10 3
0.01
10 4 10 5
10 6
10 7 10 8
10 9
Frequency [Hz]
Fig. 21: Dielectric constant and dissipation factor for glass-fiber
reinforced Ultradur® as a function of frequency
21
The properties of Ultradur®
Tests
Various material tests are carried out to assess the fire behavior of
electrical insulating materials.
The classification of the Ultradur® grades by the insulating material
test DIN IEC 707/ VDE 0304, Part 3 “Determination of flammability on
exposure to ignition sources” contains three test methods which can
be optionally used:
• BH method: ignition rod, horizontal arrangement of test specimen;
• FH method: Bunsen burner, horizontal arrangement of test specimen;
• FV method: Bunsen burner, vertical arrangement of test specimen.
A further test on rod-shaped specimens in the rating according to the
UL 94 standard, “Tests for Flammability of Plastics Materials for Parts
in Devices and Appliances” of the Underwriters Laboratories Inc. / USA.
The Ultradur® grades with halogen-containing fire-retardant additives
achieve the UL 94 rating of V-0 up to thicknesses of 0.8 mm (1/32”).
Ultradur® B 4400 G5 contains a flame retardant that is totally free of
halogens, antimony and elementary phosphorus, and achie­ves a UL 94
flammability rating of V-0 at 1.6 mm (1/16). Apart from this Ultradur®
B 4400 G5 achieves the highest rating concerning tracking resistance
(UL 94) class 0.
The glow wire test according to IEL 695, Part 2 -1 is carried out on
vertically arranged boards. The ignition source is an electrically heated
wire loop which presses against the surface of the board. Flame are
spread and the formation of burning drops assessed. The glowing wire
test is becoming increasingly important for electrical engineering components. The ratings of the Ultradur® grades are listed in Table 3.
In motor vehicle construction DIN 75200 is used as the test method
for determining the flammability of materials in the interior of vehicles.
Plate-like specimens arranged horizontally are tested with a Bunsen
burner flame, a method which is largely equivalent to FMVSS 302
( USA). As can be seen in the product range overviews all Ultradur®
grades meet the requirements (burning rate < 100 mm /min.) set for
plates up to a thickness of 1 mm.
The test on building materials for the construction industry is carried
out in accordance with the supplementary provisions of DIN 4102 “Fire
behavior of building materials and building parts”. Plates made from the
unreinforced and glass-fiber reinforced Ultradur® grades are rated as
normally flammable building materials (designation in accordance with
the building regulations in the Federal Republic of Germany) in Building
Materials Class B 2. The test results are summarized in Table 3.
Table 3: Fire behavior
Ultradur®
DIN IEC 707/ VDE 0304 T3
Method
BH FH FV
B 4520 Z2
–
B 4500
FH 3 – 20 mm /min
B 4520
B 4300 G2 – G10
DIN 53459
ISO 181
DIN 75200 / FMV SS 302
Flame spread
[mm /min]
VDE0470
§ 26
< 100
II c
HB / HB
+ 1
+
FH 3 – 20 mm /min
II c
HB / HB
850
+
+
BH 2 – 50 mm;
FH 3 – 15 mm /min
II c
HB / HB
< 750
< 100
+
HB
760
< 100
+
FV2
II b
HB / –
< 750
< 100
+
B 4406 G4 – G6 FV0
II b
V-0 / V-0
960
+
+
B 4400 G5 3
–
–
V-0 / V-2
960
+
+
2
1
+ means requirement fulfilled, flame extinguishes before the first mark
with halogen-containing flame retardants
3
with halogen-free flame retardants
2
22
Glow wire (OC)
(3 mm wall thickness)
DIN IEC 695 Teil 2-1/
VDE 0471 Teil 2-1
HB / –
S 4090 G4 – G6
B 4300 K4 – K6
UL 94
1/ 16” 1/ 32”
T H E PR O PE R T I E S OF Ult raDUR ®
Door handle
Resistance to chemicals
Behavior on exposure to weather
Ultradur® is highly resistant to many common solvents, such as alcohols,­
ethers, esters, higher aliphatic esters and aliphatic perhalogenated
hydrocarbons, and to fats and oils, such as propellants, brake fluid and
transformer oils. The action of solvents and chemicals is described at
length in our Technical Information leaflet “Resistance of Ultramid®,
Ultraform® and Ultradur® to chemicals”.
As has been shown by 3-year exposure to weather in the open in Central Europe, moldings made from Ultradur® tend to discolor only very
slightly and their surface scarcely changes. Mechanical ­properties too,
such as rigidity, tensile strength and tear strength, are hardly adversely
affected. After a weathering test for 3,600 hours in the Xenotest 1200
device the values for tensile strength still amount to 90 % of the initial value. On the other hand elongation at break is more adversely
affected. Using Xenotest 1200 equipment, BASF simulated e. g. 5 - 6
years of weathering in the open air. Parts for outdoor use should be
manufactured from black-colored material in order to prevent impairment of strength due to surface attack. Fibre-reinforced grades such
as ­Ultradur® B 4040 G2 /G4/G6 /G10 with outstanding surface quality
and high resistance to UV radiation are suitable for parts subject to
­particularly extreme exposure. These grades have outstanding surface
quality and exhibit high resistance to UV radiation.
Solvents having an effect at room temperature are unknown. At elevated
temperatures Ultradur® is dissolved by mixtures of o-dichlorobenzene
and phenol or tetrachloroethane and phenol as well as by o-chloro­
phenol and dichloroacetic acid. At room temperature Ultradur® is stable
to water and aqueous solutions of most salts. It exhibits limited resistance to dilute acids and is not resistant to aqueous alkalis.
Polyesters are susceptible to hydrolysis, hence prolonged use of
Ultradur®­ in water or in aqueous solutions above 60 °C must be avoided. Brief contact with warm or hot water is not a problem. Ultradur®
B 4030G6 is available as a special grade for cases where improved
resistance to hydrolysis is a particular requirement.
Stress cracking of Ultradur® due to solvents or other chemicals has so
far not been observed. Clearance for the use of the material for highly
stressed components in potentially aggressive chemicals requires that
its chemical suitability be reliably demonstrated. This may be done on
the basis of experience with similar parts made of the same material in
the same medium under similar conditions or by testing the part under
conditions in practice.
Wire loop
(max. 960 °C)
Specimen
1N
Test rig
Tissue paper
Fig. 22: Incadescent wire test
23
The processing of Ultradur®
As a general rule Ultradur® can be processed by all
methods known for ­thermoplastics. The main methods which come into consideration, ­however, are
injection molding and extrusion. Complex moldings
are economically manufactured in large numbers
from Ultradur® by injection molding. The extrusion­
process is used to produce film, semi-finished products, pipes, profiled parts, sheet and mono­filaments.
Semi-finished products are for the most part ma­
chined further by means of cutting tools to form finished moldings. The Ultradur® S types are especially
suitable for the Mucell® process (frothing).
General notes
Moisture and drying
Thermoplastic polyesters, such as polybutylene terephthalate (PBT) for
example, are susceptible to hydrolysis. If the moisture content ­during
fusion in the course of processing is too high, degradation will occur.
This results in cleavage of the molecular chains and hence in a reduction in the mean molecular weight.
In practice this manifests itself in a loss in impact resistance and
elasticity. The decline in strength usually turns out to be less marked.
Degradation of the material can be demonstrated by determining the
viscosity number according to DIN ISO 1628-5 or the melt volume
index according to ISO 1133.
Particular care therefore has to be devoted to pretreatment of the
­pellets and processing in order that high quality of the finished parts
and low fluctuation in quality can be guaranteed.
Ultradur® should generally have a moisture content of less than 0.04 %
when being processed.
In order to ensure reliable production, therefore, pre-drying should
generally be the rule and the machine should be loaded via a closed
conveyor system. Appropriate equipment is commercially available.
Pre-drying is also recommended for the addition of batches, e. g. in the
case of inhouse pigmentation.
In order to prevent the formation of condensed water, containers stored
in unheated rooms must only be opened when they have attained the
temperature prevailing in the processing area. This can possibly take a
very long time. Measurements have shown that the interior of a 25-kg
bag originally at 5 °C had reached the temperature of 20 °C in the processing area only after 48 hours.
Process simulation:
Calculation of the load on inserts during the charging process
Charging simulation
24
Housing with conductor strips
and retaining pins
Load calculation
Flow pattern
T he Processi n g of Ult radur ®
Loose buffer tubes for optical fibers
Of the various dryer systems possible, the dry air dryer has proved to
be technically and economically superior.
Drying times for these devices amount to 4 hours at 80 °C to 120 °C.
In general the directions of the equipment manufacturer should be
observed in order to achieve the desired drying effect. The use of
vented screws is inadvisable.
Production stoppages and change of material
During brief production stoppages the screw should be advanced to
the forwardmost position and when downtimes are relatively long the
barrel temperature should be additionally lowered. Before restarting
after stoppages thorough purging is required.
Reprocessing
Reprocessing of reground parts and sprue is usually possible. Since,
however, degradation to a greater or lesser degree can occur in each
processing cycle checks should first of all be made as to how extensive this is in the case in question. Checks on the viscosity number in
solution or the melt viscosity provide useful information.
If the material was handled gently in the first pass then as a rule up to
25 % of the regranulated material can be mixed with the fresh granules
without any appreciable decline in the characteristics of the material.
In the case of flame retardant products limits to the quantity of regrind
permitted have to be observed (e. g. by means of UL specifications).
When regrind is added care has to be taken that there is adequate
predrying (see section on “Moisture and drying”).
When there is a change of material the screw and barrel must be
cleaned in advance. HDPE of high molecular weight as well as glassfiber reinforced HDPE and GFPP have proved to have good cleaning
action in such cases.
Structure simulation
Loading
Deformation and stress
25
Moisture content [Wt.-%]
The processing of Ultradur®
Self-coloring
Further shades other than those in our product range can be made up
by means of self-coloring using masterbatches. When choosing the
masterbatch attention should be paid to a high level of compatibility
with Ultradur® so that its range of properties is not affected. We recommend PBT-based color batches.
0.10
0.09
0.08
B 4520
0.07
0.06
In the case of flame-retardant products care must be taken that
only masterbatches are used which do not change its rating (e. g.
according to UL).
0.05
0.04
0.03
0.02
0.01
0.00
Our Ultraplaste-Infopoint will be happy to provide you with the addresses
of suppliers of suitable masterbatches.
24°C/59 % rel. humidity
24°C/94 % rel. humidity
0
100
200
300
400
500
600
Storage time [min]
R
D hA
LA
S
Flight depth h [mm]
Fig. 23: Absorption of moisture by unreinforced Ultradur® as a
function of time
hE
LK
LE
12
hE = flight depth in the feed section
hA = flight depth in the metering section
10
standard screw
shallow screw
8
L
6
D
L
LE
LK
LA
hA
hE
S
R
outer diameter of the screw
effective screw length
length of feed section
length of compression section
length of metering section
flight depth in the metering section
flight depth in the feed section
pitch
non-return valve
18-23
0.5-0.55
0.25-0.3
0.2
D
L
L
L
0.8-1.0
D
Fig: 24: Screw geometry – terms and dimensions for three-section
screws for injection-molding machines
26
4
2
hE
hA
30 40 50 60 70 80 90 100 110 120 130
Screw diameter-Ø D [mm]
Fig: 25: Screw geometry and screw flight depths for three-section
screws in injection-molding machines
T he Processi n g of Ult radur ®
Plug-in connector
Injection molding
Injection unit
What is known as the “normal screw” is suitable for processing
­Ultradur®. A single-flighted, shallow-cut three-section screw having
a L / D ratio of 18 - 22 D is better for PBT. For the same screw diameter
shallow flighted screws ensure a shorter residence time of the melt
in the cylinder and a more homogeneous temperature distribution in
the melt.
When processing GF-reinforced PBT grades hard-wearing steels
should be used for the cylinder, screw and non-return valve. At higher
holding pressures the non-return must also prevent backflow of the
melt out of the space in front of the screw so that sink marks or voids
in the part are reliably avoided. The need for a check on the adequacy
of sealing or excess play is always indicated when the melt cushion in
the filled mold reduces markedly in the holding phase.
Due to the viscous melt Ultradur can be processed both with an
open nozzle as well as with a shut-off nozzle. The use of nozzle
heater bands is recommended.
®
Mold design
For Ultradur® both conventional cold runners as well as hot runner
­systems can be used.
Diversions have to be designed in a manner favoring flow in order to
avoid deposits. Here furthermore, good thermal isolation at the gate
is important. In this way the temperatures of the heated and cooled
regions can be more directly controlled and the total energy requirements for heating and cooling are reduced.
The most suitable type of gate depends on the specific application and
must therefore be selected for each case.
At mold temperatures above 60 °C the installation of thermal insulation
panels between the machine platen and the mold base plate should
be considered. As a result less heat energy is lost and the temperature
distribution in the mold is more uniform.
Temperature control in the mold should be so effective that even over
long production periods the desired temperatures are attained in all
contour-forming regions or selective temperature changes can be
produced at particular points by means of independent temperature
control circuits. The quality of an effective cooling system is shown in
that temperature fluctuations during the cycle phase are as small as
possible. Draft angels of 1° per side allow problem-free demolding.
27
The processing of Ultradur®
Metering and back pressure
When metering in, the peripheral screw speed and the level of back
pressure have to be limited with a view to gentle handling of the
­material.
Gentle infeed is guaranteed for peripheral screw speeds of up to
15 m /min. Figure 26 shows the speeds to be set as a function of the
screw diameter.
On the basis of experience the back pressure, which should ensure
improved homogeneity of the melt and is therefore desirable, should,
however, be limited to 10 bar due to the risk of excessive shear.
Good feed behavior is best achieved by means of rising temperature
control. This is illustrated by way of example in Figure 27.
Processing temperature and residence time
The recommended range of melt temperatures for the various ­Ultradur®
grades is 250 °C to 270 °C. In order to work out the optimum machine
setting experience suggests that a start should be made at the temperature of 260 °C.
The choice of melt temperature depends on the flow lengths and wall
thickness and on the residence time of the melt in the cylinder.
Unnecessarily high melt temperatures and excessively long residence
times of the melt in the cylinder can bring about molecular degradation. Figure 28 shows an example illustrating how the viscosity number
acts as a measure of the molecular weight as a function of the melt
temperature and residence time.
Peripheral speed [m/min]
Based on experience material degradation of less than 10 % based on
the measured viscosity in solution of the granules and the molding is
tolerable. In the event of values higher than this the processing parameters and pretreatment should be checked.
60
Screw diameter-Ø D (mm)
55
60
50
45
45
40
Maximum
recommended
speed
15 m/min
35
30
Heaters
6
5
4
25
20
20
15
15
Temperature
control
260
2
260
260
260
260
260 60 °C
240
235 60 °C
risin g
5
260
0
50
100
150
200
250
255
250
245
300
Rotary speed [rpm]
Fig: 26: Peripheral screw speed as a function of rotary speed and
screw diameter
28
1 Hopper
steady
10
0
3
30
Fig. 27: Cylinder temperature control for Ultradur®
T he Processi n g of Ult radur ®
Mold surface temperature
On the basis of experience mold surface temperatures should lie in the
range of 40 °C to 80 °C for unreinforced materials and 60 °C to 100 °C
for reinforced materials. These temperatures can usefully be attained
using water systems.
Flow behavior and injection speed
In general the plastic melt should be injected into the injection-mold
as rapidly as possible. However, in the case of particular component
geometries and gate types it may be necessary to reduce the injection
rate.
In the case of components with high demands on surface quality, especially in the case of glass-fibre reinforced grades, care should be taken
that the mold surface temperature is at least 80 °C or higher.
The flow behavior of the melt is of great importance for the charging of
the mold. It can be assessed using spiral molds on commercial injection molding machines. The path covered in this mold is a ­measure of
the flow properties.
Since the mold temperature has an effect on shrinkage, warpage and
surface quality it is of great importance for the dimensional accuracy
of parts.
In Figure 29 the spiral lengths for some selected Ultradur® grades are
presented.
B 4520
130
120
240°C
110
250°C
260°C
100
270°C
500
450
400
Melt temperature 260 °C
Melt temperature 280 °C
350
300
250
90
200
80
300°C
290°C
150
280°C
100
70
60
Spiral length [mm]
Viscosity number [ml/g]
The trend of the effect of mold surface temperature on shrinkage
behavior is illustrated in Figures 32 to 35 with reference to the examples of Ultradur® B 4520 and B 4300 G6. Ultradur® S 4090 G2-G6
represent grades having especially low warpage.
50
0
0
5
10
15
20
25
30
35
Residence time in the plasticating unit [min]
Fig. 28: Polymer degradation (as measured by the drop in viscosity
number) in Ultradur® test specimens as a function of the melt
temperature and residence time in the plastication unit
B 4300 G2 B 4300 G4 B 4300 G6 S 4090 G4 S 4090 G6
Fig. 29: Flow behavior of glass-fiber reinforced Ultradur® grades;
spiral length as a function of melt temperature; wall thickness 1.5 mm
29
The processing of Ultradur®
Shrinkage
DIN 16901 defines the terms and test methods for shrinkage in processing. According to this shrinkage is defined as the difference in the
dimensions of the mold and those of the injection-molded part at room
temperature. Shrinkage is primarily a property of the material but it is
also determined by the geometry (free or impeded shrinkage) and the
wall thickness of the injection molding.
In addition the position and size of the gate and the processing parameters (melt and mold temperature, pressure and holding time) together
with the storage time and storage temperature play a decisive role. The
interaction of these various factors makes exact prediction of shrinkage
very difficult.
B
The extent of shrinkage in a particular component depends on many
factors. The most important ­determining factors are listed below.
• The geometry of the injection-molded part (differences in wall
thickness, free or impeded shrinkage)
• The process technology used in production ( holding pressure, mold
surface temperature, melt temperature, injection rate, etc.)
• Type and arrangement of the gate ( pin, sprue or film gate)
• The orientation of the glass fibers ( parallel or transverse with respect
to the direction of flow)
• The storage period after cooling (aftershrinkage)
• The storage temperature ( tempering effect )
1
2
3
4
5
6
1000
A
C
E
D
In the Ultradur® product range guide values for shrinkage are given.
These guide values were determined for boards having a thickness
of 3 mm which were able to shrink freely. The melt temperature was
260 °C while the mold temperature was 60 °C for unreinforced and
80 °C for reinforced materials and the holding pressure was 500 bar.
Injection pressure [bar]
Injection pressure
The required injection pressure very much depends on the flow properties of the material, the type of gate and the geometry of the molding.
Figure 30 depicts the test box used by way of example for carrying out
injection pressure tests. Figure 31 shows plots of injection pressure for
some selected Ultradur® grades as a function of the melt temperature.
A ≈ 107
B ≈ 47
C ≈ 40
D ≈ 60
E ≈ 120
mm
mm
mm
mm
mm
=
=
=
=
=
=
B
B
B
B
B
B
4300
4300
4300
4300
4300
4520
G10
G6
K4, K6
G4
G2
Z2
1
2
3
4
500
5
6
Fig. 30: Test box
250
260
270
Melt temperature [°C]
Fig. 31: Flowability as a function of melt temperature.
Machine: 800 kN, cycle time = 20 s, screw diameter = 30 mm,
mold surface temperature = 80 °C, injection speed = 16 mm /s
30
T he Processi n g of Ult radur ®
500
2.0
1000
500
1500
1.5
1000
Holding pressure [bar]
Shrinkage [%]
B 4520
1500
In order to illustrate the effect of some of these parameters the shrinkage is presented by way of example as a function of the mold surface
temperature for wall thicknesses of 1.5 and 3 mm for unreinforced
Ultradur® B 4520 in Figure 32 and for glass-fiber reinforced Ultradur®
B 4300 G6 in Figure 33. Additionally in this investigation the holding
pressure was varied in stepwise manner from 500 through 1000 to
1500 bar. The test component was a test box as shown in Figure 30.
The specified shrinkage values were measured along the longitudinal
direction of the box.
1.0
0.5
0
20
30
40
50
60
70
80
90
Mold surface temperature [°C]
Melt temperature
Wall thickness ≥ 3.0 mm
(MT) 260 °C
Wall thickness = 1.5 mm
Holding pressure [bar]
Shrinkage [%]
Fig. 32: Shrinkage diagram for unreinforced Ultradur®
B 4300 G6
1.0
0.8
500
0.6
Depending on the processing conditions, aftershrinkage of the com­
ponents can occur. Figure 34 for unreinforced Ultradur® B 4520 and
Figure 35 for glass-fiber reinforced Ultradur® B 4300 G6 give an
impression of how large aftershrinkage can be as a function of the
mold surface temperature.
After storage for 60 days at room temperature only the molded parts
produced at low mold temperatures exhibited small dimensional variations (about 0.1 %). After tempering, i. e. hot storage for 24 hours at
120 °C, the same parts exhibited marked aftershrinkage, especially
those produced at low mold temperatures. As the mold surface temperature rises aftershrinkage steadily drops. This behavior should be
taken into account when designing parts for use at elevated operational temperatures.
The Ultradur® grades S 4090 G2-G6 represent alternatives having
lower shrinkage. Their shrinkage and warpage behavior are compared
with those of the Ultradur® B 4300 and B 4040 grades (20 % GF) in
Figures 36 and 37.
1000
1500
0.4
20
30
40
50
60
70
80
90
Mold surface temperature [°C]
Melt temperature
Wall thickness ≥ 3.0 mm
(MT) 260 °C
Wall thickness = 1.5 mm
Fig. 33: Shrinkage diagram for glass-fiber reinforced Ultradur®
Headlamp bezels
31
2.0
Shrinkage [%]
Shrinkage [%]
The processing of Ultradur®
Wall thickness 2 mm
5
1.5
1.0
5
0.8
0.6
B 4520
1.0
Wall thickness 1 mm
1.2
4
3
2
1
0.4
0.2
0.5
20 30 40 50 60 70 80 90 100 110 120 130
Mold surface temperature [°C]
1100 kN
265°C
Machine:
Plastic temperature:
test box
Mold:
660 bar
Holding pressure:
Wall thickness: 2 mm
Dimension measured A: 107 mm
Fig. 34: Effect of mold temperature and post-molding conditions on
the shrinkage of unreinforced Ultradur®.
0
20
B 4300 G6
4
3
1/2
30
40
50
Machine:
1100 kN
Mold:
test box
Wall thickness: 1 mm
60 70 80 90 100 110 120
Mold surface temperature [°C]
Plastic temperature:
265°C
Holding pressure:
660 bar
Dimension measured A: 107 mm
Fig. 35: Effect of mold temperature and post-molding conditions on
the shrinkage of glass-fiber reinforced Ultradur®
1 Shrinkage measured 1 hour after injection.
2 Shrinkage measured 24 hours after injection.
3 Shrinkage measured 14 days after injection.
4 Shrinkage measured 60 days after injection.
5 Shrinkage measured after tempering ( for 24 hours at 120 °C)
Table 4: Table of corrections for shrinkage calculations [%]
Melt temperature 250 °C
Holding pressure PN
[bar]
TMold* 40 °C
TMold* 80 °C
500
1000
1500
+ 0.05
+ 0.08
+ 0.10
+ 0.08
+ 0.10
+ 0.15
Holding pressure PN
TMold* 40 °C
TMold* 80 °C
– 0.05
– 0.08
– 0.10
– 0.08
– 0.10
– 0.15
1.5 mm wall thickness
3.0 mm wall thickness
[bar]
TMold* 40 °C
TMold* 80 °C
TMold* 40 °C
TMold* 80 °C
500
1000
1500
+ 0.20
+ 0.20
+ 0.15
+ 0.30
+ 0.25
+ 0.20
– 0.30
– 0.25
– 0.20
– 0.40
– 0.35
– 0.25
* TMold = Mold temperature
32
Melt temperature 270 °C
T he Processi n g of Ult radur ®
Steering wheel module
Warpage
The warpage of an injection-molded part is caused mainly by differential shrinkage in the direction of flow and in the direction transverse to
this. Warpage is often particularly noticeable in the case of glass-fiber
reinforced materials. In addition, this increases as the mold surface
temperature rises.
On the other hand shrinkage in the direction of flow and transverse
to this is approximately the same in unreinforced, mineral-filled and
glass-bead filled products. Injection-moldings which due to their design
tend particularly readily to warp should therefore be manu­factured as
far as possible from these Ultradur® grades or from the lower-warpage
glass-fiber reinforced Ultradur® S grades.
In many cases warpage-free moldings can be produced by differential
temperature control of the mold parts.
0.42
B 4300 G4
1.25
1, 1.0
B 4300 G4
0.38
B 4040 G4
0,80.8
B 4040 G4
1.0
0.25
S 4090 G4
0.2
0.4
parallel to melt flow
perpendicular to melt flow
0.6
0.3
B 4090 G4
0.67
0.8
1.0
1.2
Shrinkage after 1 h [%]
Fig. 36: Shrinkage behavior of glass-fiber reinforced Ultradur®
( Test box with walls 1.5 mm thick; melt temperature = 260 °C;
mold surface temperature = 80 °C)
00
0,5
0.5
1,0
1.0
1,5
1.5
Warpage [mm]
Fig. 37: Warpage behavior of glass-fiber reinforced Ultradur®
( Test box with walls 1.5 mm thick; melt temperature = 260 °C;
mold surface temperature = 80 °C)
33
The processing of Ultradur®
Extrusion
Fundamentals, screw geometry
The following Ultradur® resins listed in order of rising viscosity are
available for extrusion:
The processing properties of the aforesaid grades are similar to those
of Polyamide 6. In general, therefore, the product can be processed on
installations suitable for polyamides.
Ultradur® B 2550
Ultradur® B 4500
Ultradur® B 6550
Ultradur® B 6550 L
Ultradur® B 6550 LN
The same is true for the screw geometry. Experience to date has
shown that all Ultradur® extrusion grades can be extruded using the
same three-section screws which have also proved to be effective in
the processing of polyamides.
Typical values for characteristic properties are given in Table 5.
Ultradur® B 2550 is suitable for the production of monofilaments and
bristles.
Ultradur® B 4500 is suitable for the extrusion of flat films, Ultradur® B
6550 for the extrusion of thin-walled and thick-walled tubes, hollow
and solid profiles and semi finished parts.
Ultradur® B 6550 L and B 6550 LN is also primarily intended for producing buffer tubes used in fibre optic cables. It fulfils the requirements
imposed by today’s trend towards higher extrusion speeds and /or better tensile properties. Ultradur® B 6550 L is additional modified with
lubricant for an better feeding performance ( for extruders with a critical
feeding behavior). Ultradur® B 6550 LN is nucleated and is recommended when tubes with a higher stiffness are required.
For Ultradur® the compression section and the flight depth ratio are
even more important than for polyamide. Rapid build-up of a sufficiently high pressure has to be ensured by choosing a screw having
a short compression section and a high flight depth ratio between the
feed and metering sections.
The length of the compression zone should, therefore, not exceed
4 - 5 D and the flight depth ratio should be approximately 3 :1. However,
good results have also been achieved using screws with short compression zones.
Extruded Ultradur® B 6550 LN profile – circular, square and hollow
rods together with sheet and flat bars are principally used as semifinished parts for machine-cutting to produce engineering articles for
which production by injection-molding does not come into consideration due to the small numbers involved.
Tubes made from Ultradur® B 6550 L and B 6550 LN are resistant
to fuels, oils and greases and for favorable sliding friction and wear
properties.
Table 5: Typical values for the characteristic properties of Ultradur® extrusion grades
34
Property
Unit
Test method
B 2550
B 4500
B 6550
B 6550 L
B 6550 LN
Density
g/cm3
ISO 1183
1.30 ± 0.01
1.30 ± 0.01
1.30 ± 0.01
Melting temperature
°C
ISO 11357-3
220 - 225
220 - 225
220 - 225
Processing temperature
°C
–
230 - 290
230 - 290
230 - 290
Melt viscosity
–
–
low
medium
high
Viscosity number
cm3/g
ISO 1628
o-dichlorobenzene, phenol 1:1,
c = 0,5 g / 100 ml solvent
approx. 107
approx. 130
approx. 160
T he Processi n g of Ult radur ®
The ability of Ultradur® tube to withstand compressive loads is remarkably high not only at normal temperatures but also at higher temperatures. They can for example withstand burst pressures higher by at
least a factor of 1.5 than polyamide tubes of comparable size.
Thin-walled pipes made from Ultradur® B 6550 L and B 6550 LN
are therefore generally suitable for fuel and oil pipes, pneumatic and
hydraulic control lines, pipes for central lubrication systems, Bowden
cables and other cable systems.
Production of semi-finished products and profile sections
Ultradur® B 6550 and B 6550 LN is formed into circular, square,
square-section and hollow rods under pressure by the cooled-die
extrusion method, i. e. with cooled or temperature-controlled mold pipes.
Due to the necessarily lengthy residence time of the melt the melt
­temperature has to be kept as low as possible. In the case of layers
thicker than 70 - 80 µm it should not exceed 250 °C.
In contrast with polyesters based on polyethylene terephthalate the
temperature of the cooled die in the case of Ultradur® need not be
elevated, i. e. temperature control can be effected with water at room
­tem­perature. If the melt temperature has to be reduced due to increasing layer thickness it is, however, more favorable in respect of surface
quality and state of stress in the parts to operate with water of higher
­tem­perature (60 °C to 80 °C; see the processing example for the produc­
tion of round-section rod in Table 6). As with other partially crystalline
thermoplastics, suitably high pressures are also needed in the case
of Ultradur® for compensating for the volume shrinkage occurring on
solidification of the melt.
Production of sheet
Ultradur® B 6550 LN sheet and slab, are produced on commercial,
horizontally arranged installations having a sheet die, three-roll polishing stack and a following take-off unit. The sheet die should have
lips which extend up close to the nip. The temperature control of the
rolls depends on the sheet thickness in question and ranges from 60
to 170 °C (for processing example see Table 7 ). The throughput and
off-take rate are matched to one another in such a way that a small,
­uniform bead is formed over the width of the roll ahead of the nip. The
uniformity of this bead is of great ­importance for the ­tolerances and
surface quality of the sheet.
Table 6: Rod extrusion example for Ultradur® B 6550 LN
Rod diameter
60 mm
Extruder
45 mm , 20 D
Screw
– Section lengths – Flight depths
L E = 9 D, L K = 3 D, L P = 8 D
h1 / h2 = 6.65/2.25 mm
Temperature settings
– Adapter
– Die (heated part)
– Die (cooled part)
235 / 245 / 250 °C
240 °C
250 °C
20 °C
Screw speed
16 U /min
Melt pressure
approx. 30 bar
Take-off speed
27 m /min
Output
5.9 kg / h
Table 7: Sheet extrusion example for Ultradur® B 6550 LN
Sheet dimensions
780 x 2 mm
Extruder
90 mm , 30 D
Screw
– 3-Section lengths
– Flight depths
L E = 11.5 D, L K = 4.5 D, L P = 14 D
h1 / h2 = 14.0 /4.3 mm
Die
800 mm wide
Temperature settings
– Hopper
– Barrel
– Adapter
– Die
40 °C
215 / 220 / 235 / 260 / 230 / 225 / 220 / 220 °C
230 °C
throughout 230 °C
Three-roll-stack
300 mm roll diameter
Temperature top
50 °C
center 115 °C
bottom 170 °C
Screw speed
34 U /min
Melt temperature
256 °C
Take-off speed
0.76 m /min
Output
100.8 kg / h
35
The processing of Ultradur®
Production of tubes
Tubes made from Ultradur® B 6550 L and B 6550 LN with diameters
up to approx. 8 mm and a wall thickness of 1 mm are produced by the
vacuum water bath calibration method. Both sizing tubes and sizing
plates are suitable for calibration. In both cases the internal diameter
is chosen to be approximately 2.5 % greater than the desired outer
diameter of the tube to be produced. Based on experience this difference corresponds to the shrinkage in processing. To achieve the highest possible haul-off speeds with Ultradur® B6550 L and B6550LN,
the ratio of the pipe die diameter to the internal diameter of the sizing
sleeve must range from about 2 :1 to 2.5 :1. The die gap of the pipe
extrusion head should be 3 to 4 times the size of the desired wall
thickness of the tube. A processing example for the production of tube
is described in Table 8.
Production of film
Flat film made from Ultradur® B 4500 is manufactured by the usual
method using slot dies and chill rolls. With appropriate cooling the films
have very good transparency and at the same time they are rigid and
have good surface slip. A processing example is reproduced in Table 9.
Table 8: Processing example for the production of tube from
Ultradur® B 6550 L and B 6550 LN
Tube dimensions
6 x 1 mm
Extruder
45 mm , 20 D
Screw
– Section length
– Flight depths
L E = 9 D, L K = 3 D, L P = 8 D
h1 / h2 = 6.65 / 2.25 mm
Temperature settings
– Extruder
– Adapter
– Die
250 / 240 / 230 °C
225 °C
215 °C
Die
– Die diameter
– Mandrel diameter
– Gap
14 mm
6.8 mm
3.6 mm
Waterbath-vacuum calibration unit
– Sizing plate diameter 6.15 mm
19 °C
– Water temperature
36
Screw speed
72 U /min
Take-off speed
20 m /min
Output
24 kg / h
Ultradur® B 4500 film of 12 - 100 µm gauge can be produced under
appropriate production conditions in thicknesses. They are highly transparent and have good surface slip and high rigidity. The properties of
such films are given in Table 10. Adhesive-tape resistant vapor deposition of aluminum is readily possible on these films. The barrier properties are improved still further by the vapor deposition.
Ultradur® B 4500 monofilm or multilayer ( with PE ) can be sterilized
on their own and in composites without risk of damage using superheated steam at 120 °C to 140 °C, ethylene oxide or ionizing radiation
(2.5 x 104 J/kg). They are therefore also suitable as a packaging material for sterilized goods.
The films made from Ultradur® B 4500 can be oriented uniaxially or
biaxially.
Ultradur® B 4500 monofilm can be welded by means of ultrasonics.
Joining is also possible using parting line welding based on the thermal
impulse principle. In this case, however, postcrystallization produces a
white zone in the area of the welded joint.
Production of monofilaments and bristles
Monofilaments made from Ultradur® B 2550 for the paper screening
fabric sector are produced on commercial extruders. The usual monofilament diameters lie in the range of 0.5 mm to 1.0 mm. To achieve
good uniformity of diameter water spinning bath temperatures of
60 °C to 80 °C are required when cooling.
In comparison with polyesters made from polyethylene terephthalate­
Ultradur® exhibits better resistance to hydrolysis which can be substantially increased by using standard stabilisers based on polycarbodiimides.
Bristles for toothbrushes are extruded from Ultradur® B 2550. Finishing treatments in the autoclave or in hot water baths for ­improving the
ability to return to the upright position are not ­absolutely necessary.
Toothbrush bristles made from Ultradur® are distinguished primarily by
low water absorption, high resistance to abrasion and excellent powers
of return to the upright position.
Examples of the production of monofilaments and bristles from
­Ultradur® are presented in Table 11.
T he Processi n g of Ult radur ®
Table 9: Film extrusion example for Ultradur® B 4500
Dimensions
Gauge approx. 30 µm, width 650 mm
Screw
– Section lengths
– Flight depths
D = 63.5 mm, L/D = 24
L E = 7 D, L K = 5 D, L P = 12 D
h1 / h2 = 8.5 / 2.5 mm
Screen pack
400, 900, 2500, 3600 mesh count /cm2
Die
Width 800, die gap 0.5 mm
Heater band temperatures 230 /245 /255 / 265 °C / die 225 °C
Melt temperature
280 °C
Melt pressure
75 bar
Chill rolls
– Temperature
– Diameter
approx. 55 °C
450 mm
Screw speed
40 U /min
Take-off speed
26 m /min
Output
44 kg / h
Table 10: Properties of film made from Ultradur® B 4500
(gauge approx. 25 µm, measured in standard atmosphere
23 ºC / 50.r. h. after saturation)
Unit
Value
Test method
Mechanical properties
Yield stress S
(para. & perp.)
MPa
30 - 35
ISO 527
Tear strength R
(para. & perp.)
MPa
75 - 80
ISO 527
Strain at break R
(para. & perp.)
%
450 - 500
ISO 527
Gas transmission
– Water vapor
transmission rate
– Nitrogen gas
transmission rate
– Oxygen
permeability
– Carbon dioxide
permeability
2
g/(m · d)
10
ASTM F 1249
ml/(m2 · d)
12
ASTM D
3985-81
Table 11: Processing examples for the production of
­monofilaments and bristles from Ultradur®
Diameter
Monofilaments Bristles
0.70 mm
0.20 mm
Extruder
D = 45 mm,
L = 25 D
Screw
three-section screw,
6 D/7 D/9 D + 3 D
Die
– Die head diameter
– Die head length
2.4 mm
4.8 mm
0.65 mm
0.90 mm
Temperature control
– Section 1
– Section 2
– Section 3
– Section 4
– Head
– Pump
– Die
– Melt
265 °C
275 °C
270 °C
265 °C
270 °C
270 °C
270 °C
270 °C
260 °C
265 °C
260 °C
255 °C
260 °C
260 °C
260 °C
260 °C
Water bath temperature
Die spacing
Cooling path length
70 °C
160 mm
900 mm
45 °C
40 mm
780 mm
– Take-off rate
– Stretching temperature (hot air),
1st heater
– Stretching unit 1
– Stretching temperature (hot air),
2nd heater
– Stretching unit 2
– Fixing temperature, 3rd heater, 20 m /min
– Fixing unit
20 m /min
155 °C
25 m /min
160 °C
80 m /min
235 °C
112.5 m /min
–
110 m /min
230 °C
–
200 °C
101.2 m /min
101.3 m /min
Stretching ratio 1
Stretching ratio 2
Overall stretching ratio
Mechanical shrinkage
1: 4.0
1: 1.38
1: 5.5
8 %
1: 4.5
–
1: 4.5
10 %
ml/(m2 · d · bar) 60
ml/(m2 · d · bar) 550
Optical properties
Haze
%
1
ASTM D 1003
37
The processing of Ultradur®
Steering angle sensor
Fabrication and finishing processes
Machining
Semi-finished parts and moldings made from Ultradur® can be readily
machined with cutting tools. This includes drilling, turning on a lathe, tapping, sawing, milling, filing and grinding. Special tools are not necessary.
Machining is possible using standard tools suitable for machining steel on
all standard machine tools.
As a general rule cutting speeds should be high and feed rate low with
rapid removal of shavings and chips. The cutting tools must always be
sharp. Since Ultradur® has a high softening point cooling is generally not
required. However, the working conditions must be chosen in such a way
that the temperatures do not exceed 200 °C.
38
Joining methods
Parts made from Ultradur® can be joined at low cost by a variety of
methods. The mechanical properties of Ultradur®, especially its toughness, allow the use of self-tapping screws. Ultradur® parts can be
connected without difficulty to one another or to parts made from other
materials by means of rivets and bolts. Ultradur®’s outstanding elasticity
and strength, even at high temperatures, enables economic manufacture of high-performance snap- and press-fitting connectors.
Ultradur® parts can be bonded to other parts made of this or another
material using two-component adhesives based on epoxide resins,
polyurethanes, silicones or even cyanoacrylates. The highest bonding
strengths can be achieved when the surfaces to be joined together are
roughened and degreased with a solvent such as acetone.
T he Processi n g of Ult radur ®
Known methods for welding Ultradur® include heating-element and
ultrasonic welding as well as spin and vibration welding. Apart from
being a gentle joining technique, laser welding is an attractive option
for joints that are subjected to little or no stress. Only high-frequency
welding is not feasible for this plastic on account of the low dielectric
loss factor. Due to its range of variation the ultrasonic joining technique
in particular affords the possibility of integrating the bonding of massproduced injection-molded parts efficiently and synchronously into fully
automated production flows. Design of the mating surfaces in line with
the welding technique together with optimum processing parameters
are the prerequisites for obtaining high-quality welded joints. It is
therefore important to consider at the design stage how parts are to be
welded and then to design the mating surfaces accordingly.
Further details can be found in the corresponding guidelines of the
DVS (Deutscher Verband für Schweißtechnik = German association
for welding technology). Ultrasound also can be used to embed metal
inserts into preformed holes.
Printing, embossing, varnishing and metallization
The recommended binders for flexo and intaglio printing are a polyamide resin or a polyamide resin in association with nitrocellulose and for
letterpress printing a standard printing varnish free of mineral oil. Twocomponent printing inks are particularly suitable for screen printing.
Stoving at temperatures of 80 °C to 120 °C ensure the best results with
respect to resistance to scratching and adhesive tapes.
Very good results are also obtained with laser-printing on Ultradur®
moldings. There is an abundance of experience in this area which we
will be happy to share. Special tints for high-contrast laser-lettering
are available at our Ultraplaste-Infopoint. Our LS types are especially
suited for that method.
Ultradur® can be chrome-plated without difficulty and hot-stamped with
suitable embossing foils.
Ultradur® can be coated with various coating systems, such as hydrosoft paints for example.
Priming and painting systems for the automotive industry are also
known which permit on-line coating of Ultradur® at temperatures of
up to 160 °C. In doing so it has to be borne in mind that in addition to
the normal molding shrinkage, further shrinkage of 0.1 - 0.2 % appears
when painted parts are stoved. The exact level of shrinkage depends
on the oven temperature.
Ultradur® parts can be metallized in high vacuum. Both vapor and sputter deposition techniques ­produce high gloss surface finishes. Ultradur®
moldings can be colored in a dye bath using water-dispersible pigments­.
Printing of the highest quality on Ultradur® is obtained by heat transfer
printing using subliming disperse dyestuffs.
Air flow sensor
39
General information
Safety notes
Safety precautions during processing
Ultradur® melts are thermally stable at temperatures up to 280 °C and
do not give rise to hazards due to molecular degradation or the evolution of gases and vapors. Like all thermoplastic polymers, however,
Ultradur® decomposes on exposure to excessive thermal stresses, e. g.
when it is overheated or as a result of cleaning by burning off. In such
cases gaseous decomposition products are formed. Decomposition
accelerates above 300 °C approximately, the initial products formed
being mainly tetrahydrofuran and water. At temperatures above about
350 °C small quantities of aldehydes and saturated and unsaturated
hydrocarbons are also formed. When Ultradur® is properly processed
and there is adequate suction at the die no risks to health are to be
expected. The workplace should be adequately ventilated when Ultradur®­
is being processed.
Food safety legislation
Some standard-grades of our Ultradur® product line are in conformity
with the current regulations for food contact in Europe and USA with
respect to their composition. In addition the Recommendations of
the German BfR, – The governmental institute for risk assessment
­(Bundesinstitut für Risikobewertung, former BgV V/ BGA) – are fulfilled.
In case of detailed information about the food contact status for a
certain standard grade, a colored Ultradur® grade or a special grade
please contact BASF Aktiengesellschaft (plastics.safety@basf.com)
directly. We are pleased to send you a food contact compliance letter
with respect to the regulations in force at present.
Delivery and storage
Incorrect processing includes e. g. high thermal stresses and long
residence times in the processing machine. In these cases there is the
risk of elimination of pungent-smelling vapors and gases which can be
a hazard to health. Such a failure additionally becomes apparent due to
brownish burn marks on the moldings. This is remedied by ejection of
the machine contents into the open air and reducing the cylinder temperature at the same time. Rapid cooling of the damaged material, e. g.
in a water bath, reduces nuisances caused by odors. In general measures should be taken to ensure ventilation and venting of the work
area, preferably by means of an extraction hood over the cylinder unit.
Standard packaging includes the 25-kg bag and the 1000 kg octabin
(octagonal container). Other forms of packaging are possible subject
to agreement. All containers are tightly sealed and should be opened
only immediately prior to processing. Further precautions for preliminary treatment and drying are described in the processing section of
the brochure. The bulk density is depending on the product about
0.5 to 0.8 g /cm3.
Ultradur® and the environment
Halogen-containing flame-retardant Ultradur® grades can give rise
to corrosive and harmful degradation products due to overheating or
long residence times of the melt in the cylinder. When relatively long
downtimes occur it is therefore necessary to flush the cylinder empty
or to purge it with an Ultradur® grade which is not flame-retardant and
lower the temperature. In general we recommend careful ­extraction by
suction in the area of the nozzle. In the event of fires involving flameretardant grades containing halogen compounds toxic compounds can
be produced which should not be inhaled.
Toxicological information, regulations
Ultradur® grades are not hazardous substances. No detrimental effects
to people engaged in the processing of Ultradur® have come to light
when the material has been correctly processed and the work areas
have been well ventilated.
40
Storage and transportation
Under normal conditions Ultradur® can be stored for unlimited ­periods.
Even at elevated temperatures, e. g. 40 °C in air, and under the action
of sunlight and weather no decomposition reactions occur (cf. sections
“Delivery and storage” and “Outdoor ­performance”).
Ultradur® is not a hazardous material as defined by the German ordinance on hazardous materials of 26.08.86 and hence is not a hazardous material for purposes of transportation (cf. Ultradur® safety data
sheet).
Ultradur® is assigned to the German water pollution class 0, i. e.
­Ultradur® poses no risk to groundwater.
Gen e ra l i n fo rmation
Ultradur® Nomenclature
Waste disposal
Subject to local authority regulations Ultradur® can be dumped or incinerated together with household garbage. The calorific value of unreinforced grades amounts to 29,000 to 32,000 kJ/kg (Hu according to
DIN 51900).
Ultradur® commercial grades are designated by either the letter B or S,
followed by a four-digit number.
The burning behavior of Ultradur® is described in the section “Ultradur®
and its characteristic properties”.
The letter behind the number denotes reinforcement or filler materials:
Recycling
Like other production wastes, sorted Ultradur® waste materials, e. g.
ground up injection-molded parts and the like, can be fed back to
a certain extent into processing depending on the grade and the
demands placed on it. You can find further information about this under
the item (see section “Reprocessing and recycling scrap”).
Ultradur® B = PBT or PBT + PET
Ultradur® S = PBT + ASA
G = glass fibers
K = glass beads
M= minerals
and the number after this denotes the approximate amount of
additive, e. g.:
2 = 10 parts by weight
4 = 20 parts by weight
6 = 30 parts by weight
10 = 50 parts by weight
Quality management certification
Quality management is a central component of BASF’s corporate
­strategy. A major goal is customer satisfaction.
The Business Unit Engineering Plastics Europe of BASF Aktien­gesell­
schaft has a quality assurance system in ­accordance with ISO/ TS
16949 certified by the German Association for the Certification of Quality Management Systems (DQS). The certification includes all services
which the business unit provides in connection with the development,
production and marketing of Ultraplasts: product and process development, production and customer service. Constant internal audits and
training programs for staff ensure the continuing operational capability
and steady development of the quality assurance system.
Color shades are identified by the code for the grade in ­question followed by the name of the color and a three- to five digit color number.
Colors
Uncolored Ultradur® has an opaque white color.
Ultradur® grades are supplied in both uncolored and colored forms. All
shades are free of cadmium pigments.
Ultradur® grades can also be colored by customers themselves. Our
Ultraplaste-Infopoint will be happy to provide further information on
request.
Connectors
41
General information
Kunststoffe der BASF
Das Sortiment auf einen Blick
Subject Index
Absorption of moisture 26
Impact failure energy 16
Adhesion 12
Air flow sensor 39
Airbag connector 21
Automotive electronics 11
Automotive engineering 4
Impact strength 16
Incadescent wire test 23
Injection molding 27 ff.
Injection pressure 30
Injection speed 29
Injection unit 27
Instrument panel 13
Back pressure 28
Behavior on exposure to weather 23
Bristles 8
Joining methods 38 f.
Charging simulation 24
Circuit breaker 7
Clip 5
Coefficient of sliding friction 19
Colors 11, 41
Cylinder temperature control 28
Load calculation 24
Loading
– cyclic 18
– long-term static 16
Loose buffer tubes for optical fibers 6, 24
Low-temperature impact resistance 16
Recycling 41
Regulations 40
Residence time 28
Resistance to chemicals 23
Delivery 40
Dial caliper 9
Dielectric constant 21
Dielectric dissipation factor 21
Door handle 23
Drying 24
Machining 38
Safety notes 40
Masterbatch distribution 11
Mechanical engineering 8
Mechanical properties 14 ff.
Mechatronic control unit 7
Metallization 39
Metering 28
Mirror acuator housing 4, 19
Modulus of elasticity 14
Moisture 24
Mold design 27
Mold surface temperature 29
Molex connector 12
Motor circuit breakers 21
Moving platen 20
Screw geometry 26, 34 f.
Self-coloring 26
Shear modulus 14
Shower head 9
Shrinkage 30 ff.
Sliding roof frame 5
Steering angle sensor 6
Steering wheel module 33
Storage 40
Stress-strain diagrams 16, 17, 18
Structure simulation 25
Eco-efficiency analysis 12
Electrical engineering and electronics 6
Electrical properties 21
Elongation 14
Embossing 39
Environment 40 f.
Exposure to heat 20
Extrusion 34 ff.
Fabrication 38 f.
Finishing processes 38 f.
Fire behavior 21 f.
– General notes 21
– Tests 22
Flexural fatigue strength 18
Flow behavior 29
Flowability 30
Food safety legislation 40
General notes 24 ff.
Headlamp 4, 31
Heat aging resistance 20
42
Production of
– Bristles 36, 37
– Films 36, 37
– Monofilaments 36, 37
– Profile sections 35
– Semi-finished products 35
– Sheet 35
– Tubes 36
Properties 10 ff.
Pump pressure housing 9
Nanotechnology 10
Nomenclature 41
Peripheral screw speed 28
Plug-in connector 5, 8, 27
Polymer degradation 29
Precision engineering 8
Printing 39
Process simulation 24
Processing example 35, 36, 37
Processing temperature 28
Product range 10, 13
Quality management certification 41
Tensile strength 15
Test box 30
Thermal properties 20
Three-section screw 26
Toughness 16
Toxicological information 40
Transportation 40
Tribological properties 19
Ultradur
®
High Speed 10 ff.
Varnishing 39
Viscosity 10
Warpage 33
Waste disposal 41
Yield stress 15
Autofroth®*
Polyurethane system
PU
Basotect ®
Foam from melamine resin
MF
Capron®
Polyamide
PA
Cellasto®*
Components made from microcellular PU elastomers
PU
CeoDS®*
Multifunctional composits made from Cellasto components
PU
Colorflexx ®
Service for the self-coloring of polystyrene and ABS
CosyPUR®*
PU soft foam system
Ecoflex ®
Biodegradable plastic /polyester
PU
Ecovio®
Biodegradable plastic /polyester on the basis of renewable raw materials
Elastan®*
Systems for sports field surfaces
PU
Elastoclear ®*
PU system
PU
Elastocoat ®*
PU systems as coating and casting compounds
PU
Elastocoast ®*
PU systems as coating and casting compounds
PU
PU
Elastocore®*
PU cast system
Elastoflex ®*
Soft polyurethane foam systems
PU
Elastofoam®*
Soft integral polyurethane foam systems
PU
Elastollan *
Thermoplastic polyurethane elastomers
PU
Elastolit ®*
Rigid integral polyurethane foam systems and RIM systems
PU
Elastonat ®*
Flexible integral polyurethane systems
PU
Elastopan®*
Polyurethane shoe foam systems
PU
Elastopir ®*
Rigid polyurethane foam systems
PU
Elastopor ®*
Rigid polyurethane foam systems
PU
Elastoskin®*
Flexible integral polyurethane systems
PU
Elastospray ®*
PU spray foam system
PU
Elasturan®*
Systems as cold curing cast elastomers
PU
®
Lupranat ®*
Diisocyanates
PU
Lupranol®*
Polyether polyols
PU
Lupranol®* Balance
Polyether polyols
PU
Lupraphen®*
Polyether polyols
PU
Luran®
Styrene /acrylonitrile copolymer
SAN
Luran® S
Acrylonitrile /styrene /acrylate polymer
ASA
Luran® SC
Acrylonitrile /styrene /acrylate polymer and polycarbonate
ASA + PC
Miramid®
Polyamide
PA 6, PA 66
Neopolen® E
Polyethylene foam
EPE
Neopolen® P
Polypropylene foam
EPP
Neopor ®
Expandable polystyrene
PS-E
Palusol®
Alkali silicate
PERMASKIN®
System for coating components
Peripor ®
Expandable polystyrene
PlasticsPortalTM
Web-based e-Commerce platform for solutions and information
PS-E
Pluracol®**
Polyether polyols
PU
Polystyrol, impact-modified
Polystyrene HIPS
PS-I
Polystyrol, standard
Polystyrene GPPS
PS
SPSTM*
Steel-polyurethane systems
PU
Styrodur ® C
Extruded rigid polystyrene foam
XPS
Styroflex ®
Styrene / butadiene block copolymer
SB
Styrolux ®
Styrene / butadiene block copolymer
SB
Styropor ®
Expandable polystyrene
PS-E
Terblend® N
Acrylonitrile / butadiene /styrene polymer and polyamide
ABS + PA
Terluran®
Acrylonitrile / butadiene /styrene polymer
ABS
Terluran® HH
Acrylonitrile / butadiene /styrene polymer
ABS
Terlux ®
Methyl methacrylate /acrylonitrile / butadiene /styrene polymer
MABS
Ultradur ®
Polybutylene terephthalate
PBT, (PBT+ ASA)
Ultraform®
Polyoxymethylene
POM
Ultramid®
Polyamide
PA 6, 66, 6 / 66, 6 / 6T
Ultrason® E
Polyethersulfone
PESU
Ultrason® S
Polysulfone
PSU
® =reg. trademark of BASF Aktiengesellschaft
®* =reg. trademark of Elastogran GmbH
®**=reg. trademark of BASF Corporation
Gen e ra l i n fo rmation
Plastics from BASF
The product range at a glance
Please visit our websites:
BASF Plastics:
www.plasticsportal.com (World)
www.plasticsportal.eu (Europe)
Additional information on
specific products:
www.plasticsportal.eu/name of product
e. g. www.plasticsportal.eu/ultradur
Polyurethanes:
www.basf.com/polyurethanes
www.elastogran.de
PVC and PVCD:
www.solvinpvc.com
Note
The data contained in this publication
are based on our current knowledge and
experience. In view of the many factors
that may affect processing and application
of our product, these data do not relieve
processor from carrying out own investigations and tests neither do these data
imply any guarantee for certain properties
nor the suitability of the product for a specific purpose. Any descriptions, drawings,
photographies, data, proportions, weights
etc. given herein may change without prior
information and does not constitute the
agreed contractual quality of the product.
It is the responsibility of the recipient of
our products to ensure that any proprietary rights and existing laws and legislation are observed. (September 2007)
TM =trademark of BASF Aktiengesellschaft
TM*=trademark of Elastogran GmbH
43
® = registered trademark of BASF Aktiengesellschaft
Tel.: +49 621 60-78780
Fax: +49 621 60-78730
E-Mail:
ultraplaste.infopoint@basf.com
KTED 0703 BE
Request of brochures:
KS / KC, E100
Fax: + 49 621 60 - 49497