Document 7Mxy5oj89DqxNRdvLk0bv29M8

A. J. Bronsky Direct: 314-242-5324 Fax: 314-242-5524 ajbronsky@bjpc.com ROWN JAMES vWNLF Law Firm July 23,2003 1010 Market Street, 20th Floor St. Louis, Missouri 63101-2000 Ms. Rosiland Robertson THE SIMMONS FIRM, LLC Attorneys at Law 707 Berkshire Blvd. East Alton, Illinois 62024 Re: Paula A. Anderson v. A. W. Chesterton, Inc., et al Cause No.: 02-L-1434 Dear Ms. Robertson: As you requested, please find enclosed a copy of the Reichhold Molding Compound Data Book, which are Bates numbered 0001-0170. Please call me if you have any questions. AJB.hmw Enclosures 7503579 St. Louis, Missouri Kansas City, Missouri Belleville, Illinois Springfield, Missouri 1v ^eponent. lnA/V\ L L ) 1 DateiJt]2rRptr AM | Reichhold Chemicals Incorporated introduced in 1960 a newphenoliwnolding compound to America. It was produced on an interrupted flight, reciprocating screw, extruder. RCI has maintained this progressive policy and continues to be the only American corporation to produce phenolic molding compounds exclusively in this type of process. It results in a scientifically controlled product which is significantly characterized by its uniformity. In 1970 RCI introduced a specifically developed lineof phenolic molding com pounds for in-line screw injection, both conventional and manifold systems. The basic formulations designed for the extrusion process proved to bean ex cellent base for the injection grades. In 1975 RCI put their world renowned polyester technology together with the, by now, established extruder compounding technology and introduced a series of Polylite thermosetting polyester molding compounds. This data book has been developed to present the phenolic molding com pounds and polyester molding compounds to you. The data are our best effort to assist you in selecting materials. We of course look forward to more direct in quiries on an individual basis and place our technical service group and laboratories at your service. % Reichhold Chemicals, Inc. P. O. Box 38, Middlesex Avenue Carteret, N. J. 07008 (201) 541-4201 0000001 ( MANUFACTURING MOLDING COMPOUNDS TECH SERVICE RESEARCH & DEVELOPMENT SALES VJ MANUFACTURING & TECH SERVICE NEW JERSEY . RESEARCH & DEVELOPMENT NEW YORK CORPORATE HEADQUARTERS NEW YORK SALES DISTRICT OFFICES ALABAMA CALIFORNIA FLORIDA GEORGIA ILLINOIS INDIANA KANSAS KENTUCKY Telephone P. O. Box 38 Middlesex Avenue Carteret, NJ 07008 201-541-4201 212-425-7836 Teletype: 710-998-0495 P. O. Box 607 Tuxedo Park, NY 10987 914-351-4724 RCI Building 525 North Broadway White Plains, NY 10603 914-682-5700 Reichhold Road Tuscaloosa, AL 35401 205-553-5620 120 South Linden Avenue S. San Francisco, CA 94080 107 South Motor Avenue Azusa, CA 91702 415-761-1585 213-283-4123 1700 Drew Street Clearwater, FL 33515 1583 N.W. 159th Street Miami, FL 33169 813-443-3222 305-621-2750 2250 N. Druid Hills Road, N.E. 404-633-4538 Atlanta, GA 30329 814 Commerce Drive Oak Brook, IL 60521 312-887-0315 1657 Commerce Drive South Bend, IN 46628 219-232-5836 3150 Fiberglass Road Kansas City KS 66115 913-321-1576 P. O. Box 7212 Louisville, KY 40207 502-897-1514 0000002 See Reverse Side (\ MANUFACTURING MOLDING COMPOUNDS TECH SERVICE RESEARCH & DEVELOPMENT JSALES V SALES DISTRICT OFFICES (continued) MASSACHUSETTSMICHIGAN MINNESOTA MISSISSIPPI MISSOURI NEW JERSEY NEW YORK NORTH CAROLINA OHIO PENNSYLVANIA TEXAS P. O. Box A Andover, MA 01810 617-475-6600 601-707 Woodward Hgts. Blvd. 313-564-6500 Detroit, Ml 48220 _ George C. Brandt, Inc. (Agent) 2975 Long Lake Road St Paul, MN 55113 612-636-6500 975 North Street Jackson, MS 39202 (New Orleans, LA District) 601-355-0523 7730 Carondefet Avenue St. Louis (Clayton), MO 63105 314-726-2929 726 Rockefeller Street Elizabeth, NJ 07202 201-353-6600 P. O. Box 863 Niagara Falls, NY 14302 716-284-8855 P. O. Box 11051 Charlotte, NC 28209 704-525-6420 11750 Chesterdale Road Cincinnati, OH 45246 20800 Center Ridge Road Cleveland, OH 44116 513-771-4446 216-331-5120 1777 Walton Road Blue Bell, PA 19422 215-542-1340 8383 Stemmons Freeway Dallas, TX 75247 2800 North Loop West Houston, TX 77092 214-638-5520 713-688-6628 0000003 r 25346 MOLDING COMPOUNDS HEAT RESISTANT/ PHENOLIC ELECTRICAL Black RCI 25346 is a two-step mineral and woodflour filled molding material. It is designed to give a smooth gloss finish in compression, transfer and injection molding applications. This material has excellent molding latitude and RCI 25346 will sustain intermittent exposure of 450F with no noticeable change in surface appearance. RCI 25346 is designed to meet the requirements of MIL-M-14 Type MFH and ASTM D 700 Types 10 and 13. DISTINGUISHING PROPERTIES f FAST CURING A HIGH GLOSS FINISH EXCELLENT MOLDING JLATITUDE V _______ - PROPERTIES TYPICAL VALUES TEST METHOD MOLDED Specific Gravity** Molding Shrinkage*** Compression Transfer Flexural Strength** Tensile Strength** Impact, Izod** Drop Strength Modulus of Elasticity in Flexure** Compressive Strength** Water Absorption** Heat Resistance Heat Deflection Customary 1.54 0.005 0.006 121,500 7,000 0.330 in./in. in./in. psi psi ft.lb./in. 25 in. 1/2# wgt. I.OxlO6 30,000 0.25 400 375 @ 264 psi psi % F F psi International System of Units 1.54 0.005 0.006 86 48 18 m/m m/m MPa* MPa* J/m 6.9 207 0.25 204 195 @ 18.5 GPa* MPa* % C C kg/cm2 ASTM D 792 ASTM D 955 ASTM D 790 ASTM D 651 ASTM D 256 (Method A) RCI Test ASTM D 790 ASTM D 695 ASTM D 570 ASTM D 794-49 ASTM D 648 * The ASTM unit of pressure or stress is the Pascal (Pa) which is equivalent to 1 Newton per square meter. ** Condition Procedure: 24 hours at 23C at 50% relative humidity. *** Shrinkage values are dependent upon internal cavity pressures and part geometry. 9/78 HEAT RESISTANT/ELECTRICAL 0000025 See Reverse Side f 25346 'N MOLDING COMPOUNDS HEAT RESISTANT/ PHENOLIC ELECTRICAL . Black , PROPERTIES ELECTRICAL Dielectric Strength! Short Time Step by Step Volume Resistivity! Arc Resistance Power Factor! 60 Hertz 1 Kilohertz 1 Megahertz Dielectric Constant! 1 60 Hertz 1 Kilohertz 1 Megahertz CTI POWDER Apparent Density Bulk Factor Granulation Preforming Plasticity Grades FLAMMABILITY TYPICAL VALUES Customary & International System of Units 370 V/mil; 300 V/mii; I.OxlO11 130 0.07 0.05 0.03 6.0 5.2 4.8 190 V 14.6 MV/m 11.8 MV/m ohm-cm seconds __ 94 V-0 0.62 gm/cc 245 10 mesh Good 8 thru 16 @ 1/8" thickness TEST METHOD ASTM D 149 ASTM D 257 ASTM D 495 ASTM D 150 ASTM D 150 ASTM D 3638 U.L. 746A!! ASTM D 1895 ASTM D 1895 U.L. 94tt t Condition Procedure: 24 hours at 23C at 50% relative humidity, tt U.L. Yellow Cards #E47849A, E47849B, E47849C, E47849C1. Reichhold Chemicals, Inc. P. O. Box 38. Middlesex Avenue Carteret. N. J. 07008 (201) 541-4201 0000026 THE INFORMATION HEREIN IS TO ASSIST CUSTOMERS IN DETERMINING WHETHER OUR PRODUCTS ARE SUITABLE FOR THEIR APPLICA TIONS. OUR PRODUCTS ARE INTENDED FOR SALE TO INDUSTRIAL AND COMMERCIAL CUSTOMERS WE REQUEST THAT CUSTOMERS INSPECT AND TEST OUR PRODUCTS BEFORE USE AND SATISFY THEMSELVES AS TO CONTENTS AND SUITABILITY. WE WARRANT THAT OUR PRODUCTS WILL MEET OUR WRITTEN SPECIFICATIONS. NOTHING HEREIN SHALL CONSTITUTE A WARRANTY EXPRESSED OR IMPLIED. INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS. NOR IS PROTECTION FROM ANY LAW OR PATENT TO BE INFERRED. ALL PATENT RIGHTS ARE RESERVED. THE EXCLUSIVE REMEDY FOR ALL PROVEN CLAIMS IS REPLACEMENT OF OUR MATERIALS AND IN NO EVENT SHALL WE BE LIABLE FOR SPECIAL. INCIDENTAL OR CONSEQUENTIAL DAMAGES. ^ 25378 ^ MOLDING COMPOUNDS PHENOLIC k MANIFOLD/ INJECTION GRADES Black j RCI 25378 Black is a two-step asbestos-free mineral and flock-filled phenolic molding compound having an excellent molded finish, low shrinkage and good heat resistance. RCI 25378 has exceptional U.L. flammability rating and good wet track resistance (CTI). RCI 25378 is designed to meet Military Specification MIL-M-14F Type MFH and ASTM D 700Types 10,13and 22. CASBESTOS FREE | DISTINGUISHING PROPERTIES GOOD ELECTRICAL PROPERTIES EXCELLENT FLAMMABILITY RATING PROPERTIES MOLDED Specific Gravity** Molding Shrinkage*** Injection Flexural Strength** Tensile Strength** Impact Izod** Drop Strength Modulus of Elasticity in Flexure** Compressive Strength** Water Absorption** Heat Resistance Heat Deflection * TYPICAL VALUES / Customary International System of Units TEST METHOD 1.61 0.055 14,000 6,800 0.32 in./in. psi psi ftlb./in. 20 in. 1/2# wgt. 1.0x10 30,000 0.20 410" 390" @ 264 psi psi % F F psi 1.61 0.055 97 47 17 m/m MPa* MPa* J/m 6.9 207 0.20 210" 199" @ 18.5 GPa* MPa* % C C kg/cm2 ASTM D 792 ASTM D 955 ASTM D 790 ASTM D 651 ASTM D 256 (Method A) RCI Test ASTM D 790 ASTM D 695 ASTM D 570 ASTM D 794-49 ASTM D 648 * The ASTM unit of pressure or stress is the Pascal (Pa) which is equivalent to 1 Newton per square meter. ** Condition Procedure: 24 hours at 23"C at 50% relative humidity. *** Shrinkage values are dependent upon internal cavity pressures and part geometry. 9/78 INJECTION 0000027 See Reverse Side ( 25378 "l MOLDING COMPOUNDS PHENOLIC MANIFOLD/ INJECTION GRADES Black PROPERTIES ELECTRICAL Dielectric Strengtht Short Time Step by Step Volume Resistivityt Arc Resistance Power Factort 60 hertz 1 Kilohertz 1 Megahertz Dielectric Constantf 60 Hertz 1 Kilohertz 1 Megahertz CTI POWDER Apparent Density Bulk Factor Granulation Preforming . Plasticity Grades FLAMMABILITY TYPICAL VALUES Customary & International System of Units 350 V/mil; 290 V/mil; I.OxlO11 180 0.15 0.06 0.03 8.5 7.2 6.5 220 V 13.8 MV/m 11.4 MV/m ohm-cm seconds _ ' , 94 V-0 0.69 gm/cc 2.4 10 mesh Good 8 thru 18 @ 1/32" thickness TEST METHOD ASTM D 149 ASTM D 257 ASTM D 495 ASTM D 150 ASTM D 150 ASTM D 3638 ASTM D 1895 ASTM D 1895 U.L. 94tt t Condition Procedure: 24 hours at 23C at 50% relative humidity, tt U.L. Yellow Cards #E47849A, E47849B, E47849C, E47849C1. Reichhold Chemicals, Inc. P. O. Box 38. Middlesex Avenue Carteret, N. J. 07008 (201) 541-4201 0000028 THE INFORMATION HEREIN IS TO ASSIST CUSTOMERS IN DETERMINING WHETHER OUR PRODUCTS ARE SUITABLE FOR THEIR APPLICA TIONS. OUR PRODUCTS ARE INTENDED FOR SALE TO INDUSTRIAL AND COMMERCIAL CUSTOMERS. WE REQUEST THAT CUSTOMERS INSPECT AND TEST OUR PRODUCTS BEFORE USE AND SATISFY THEMSELVES AS TO CONTENTS AND SUITABILITY. WE WARRANT THAT OUR PRODUCTS WILL MEET OUR WRITTEN SPECIFICATIONS NOTHING HEREIN SHALL CONSTITUTE A WARRANTY EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS. NOR IS PROTECTION FROM ANY LAW OR PATENT TO BE INFERRED. ALL PATENT RIGHTS ARE RESERVED. THE EXCLUSIVE REMEDY FOR ALL PROVEN CLAIMS IS REPLACEMENT OF OUR MA TERIALS AND IN NO EVENT SHALL WE BE LIABLE FOR SPECIAL. INCIDENTAL OR CONSEQUENTIAL DAMAGES. 25378 MOLDING COMPOUNDS HEAT RESISTANT/ ELECTRICAL PHENOLIC , Black RCI 25378 Black is a two-step asbestos-free mineral and flock-filled phenolic molding compound having an excellent molded finish, low shrinkage and good heat resistance. RCI 25378 has exceptional U.L. flammability rating and good wet track resistance (CTI). RCI 25378 is designed to meet Military Specification MIL-M-14F Type MFH and ASTM D 700 Types 10.13 and 22. CASBESTOS FREE ] DISTINGUISHING PROPERTIES GOOD ELECTRICAL PROPERTIES EXCELLENT FLAMMABILITY ___J) vRATING -PROPERTIES MOLDED Specific Gravity** Molding Shrinkage*** Compression Transfer Flexural Strength** Tensile Strength** Impact Izod** Drop Strength Modulus of Elasticity in Flexure** Compressive Strength** Water Absorption** Heat Resistance Heat Deflection TYPICAL VALUES Customary International System of Units TEST METHOD 1.61 1.61 0.003 0.0045 14,000 6,800 0.32 in./in. in./in. psi psi ftlb./in. 0.003 0,0045 97 47 17 m/m m/m MPa* MPa* J/m 20 in. 1/2# wgt. 1.0x10s 30,000 0.20 410 390* @ 264 psi 6.9 GPa* psi 207 MPa* % 0.20 %~ F . 210 c' F. 199" c . psi @ 18.5 kg/cm2 ASTM D 792 ASTM D 955 ASTM D 790 ASTM D 651 . ASTM D 256 (Method A) RCI Test ASTM D 790 ASTM D 695 ASTM D 570 ASTM D 794-49 ASTM D 648 * The ASTM unit of pressure or stress is the Pascal (Pal which is equivalent to 1 Newton per square meter. '* Condition Procedure: 24 hours at 23"C at 50% relative hun\idity. - "* Shrinkage values are dependent upon internal cavity pressures and part geometry. 9/78 HEAT RESISTANT/ELECTRICAL 0000029 See Reverse Side ry 25378 MOLDING COMPOUNDS HEAT RESISTANT/ PHENOLIC ELECTRICAL , Black PROPERTIES ELECTRICAL Dielectric Strengtht Short Time Step by Step Volume Resistivityt Arc Resistance Power Factort 60 Hertz 1 Kilohertz 1 Megahertz Dielectric Constantt 60 Hertz 1 Kilohertz 1 Megahertz CTI POWDER Apparent Density Bulk Factor Granulation Preforming Plasticity Grades FLAMMABILITY TYPICAL VALUES Customary & International System of Units 350 V/mil; 290 V/mil; I.OxlO11 180 0.15 0.06 0.03 8.5 7.2 6.5 220 V 13.8 MV/m 11.4 MV/m ohm-cm seconds - ' 94 V-0 0.69 gm/cc 2.4 10 mesh Good 8 thru 18 @ 1/32" thickness TEST METHOD ASTM D 149 ASTM D 257 ASTM D 495 ASTM D150 ASTM D 150 ASTM D 3638 ASTM D 1895 ASTM D 1895 U.L. 94tt t Condition Procedure: 24 hours at 23*C at 50% relative humidity, f t U.L. Yellow Cards #E47849A, E47849B. E47849C. E47849C1. Reichhold Chemicals, Inc. P. O. Box 38, Middlesex Avenue Carteret, N. J. 07008 (201) 541-4201 0000030 .'THE INFORMATION HEREIN IS TO ASSIST CUSTOMERS in DETERMINING whether our products are SUITABLE FOR THEIR APPLICA TIONS. OUR PRODUCTS AP.E INTENDED FOR SALE TO INDUSTRIAL AND COMMERCIAL CUSTOMERS. WE REOUEST THAT CUSTOMERS INSPECT AND TEST OUR PRODUCTS BEFORE USE AND SATISFY THEMSELVES AS TO CONTENTS AND SUITABILITY. WE WARRANT THAT OUR PRODUCTS WILL MEET OUR WRITTEN SPECIFICATIONS. NOTHING HEREIN SHALL CONSTITUTE A WARRANTY EXPRESSED OR IMPLIED. INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS. NOR IS PROTECTION FROM ANY LAW OR PATENT TO BE INFERRED. ALL PATENT RIGHTS ARE RESERVED. THE EXCLUSIVE REMEDY FOR ALL PROVEN CLAIMS IS REPLACEMENT OF OUR MATERIALS AND IN NO EVENT SHALL WE BE LIABLE FOR SPECIAL. INCIDENTAL OR CONSEQUENTIAL DAMAGES. MOLDING COMPOUNDS PHENOLIC 25379 ^ MANIFOLD/ INJECTION GRADES Brown J RCI 25379 Brown is a two-step asbestos-free mineral and flock-filled phenolic molding compound having an excellent molding finish, low shrinkage and good heat resistance. RCI 25379 has exceptional U.L. flammability rating and good wet track resistance (CTI). RCI 25379 is designed to meet Military Specification MIL-M-14F Type MFH and ASTM D 700Types 10,13and 22. DISTINGUISHING PROPERTIES CASBESTOS FREE | LOW SHRINKAGE EXCELLENT FLAMMABILITY RATING v_________ J PROPERTIES MOLDED Specific Gravity** Molding Shrinkage*** Injection Flexural Strength** Tensile Strength** Impact, laod** Drop Strength Modulus of Elasticity in Flexure** Compressive Strength** Water Absorption** Heat Resistance Heat Deflection TYPICAL VALUES Customary International System of Units TEST METHOD 1.61 0.0055 14,000 6,800 0.32 in./in. psi psi ftlb./in. 20 in. 1/2# wgt. 1.0x10 30,000 0.20 410 390 @ 264 psi Psi % F F psi 1.61 0.0055 97 47 17 6.9 207 0.20 210 199 @ 18.5 m/m MPa* MPa* J/m GPa* MPa* %. C C kg/cm2 ASTM D 792 ASTM D 955 ASTM D 790 ASTM D 651 ASTM D 256 (Method A) RCI Test ASTM D 790 ASTM D 695 ASTM D 570 ASTM D 79449 ASTM D 648 * The ASTM unit of pressure or stress is the Pascal (Pa) which is equivalent to 1 Newton per square meter. ** Condition Procedure: 24 hours at 23C at 50% relative humidity. *** Shrinkage values are dependent upon internal cavity pressures and part geometry. 9/78 INJECTION 0000031 See Reverse Side ^ 25379 ^ MOLDING COMPOUNDS PHENOLIC V MANIFOLD/ INJECTION GRADES Brown > PROPERTIES ELECTRICAL Dielectric Strengtht Short Time Step by Step Volume Resistivityt Arc Resistance Power Factort 60 Hertz 1 Kilohertz 1 Megahertz Dielectric Constantt 60 Hertz 1 Kilohertz 1 Megahertz CTI POWDER Apparent Density Bulk Factor Granulation Preforming Plasticity Grades FLAMMABILITY TYPICAL VALUES Customary & International System of Units 350 V/mii; 290 V/mil; I.OxlO11 180 13.8 MV/m 11.4 MV/m ohm-cm seconds 0.15 0.06 0.03 8.5 7.2 6.5 220 V 94 V-0 0.69 gm/cc 2.4 10 mesh Good 8 thru 18 @ 1/32" thickness TEST METHOD ASTM D 149 ASTM D 257 ASTM D 495 ASTM D 150 ASTM D 150 ASTM D 3638 U.L. 746Att ASTM D 1895 ASTM D 1895 U.L. 94tt t Condition Procedure: 24 hours at 23C at 50% relative humidity, tt U.L. Yellow Cards 0E47849A. E47849B, E47849C, E47849C1. Reichhold Chemicals, Inc. P. O. Box 38, Middlesex Avenue Carteret, N. J. 07008 (201) 541-4201 0000032 THE INFORMATION HEREIN IS TO ASSIST CUSTOMERS IN DETERMINING WHETHER OUR PRODUCTS ARE SUITABLE FOR THEIR APPLICA TIONS OUR PRODUCTS ARE INTENDED FOR SALE TO INDUSTRIAL AND COMMERCIAL CUSTOMERS WE REQUEST THAT CUSTOMERS INSPECT AND TEST OUR PRODUCTS BEFORE USE AND SATISFY THEMSELVES AS TO CONTENTS AND SUITABILITY. WE WARRANT THAT OUR PRODUCTS WILL MEET OUR WRITTEN SPECIFICATIONS NOTHING HEREIN SHALL CONSTITUTE A WARRANTY EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS. NOR IS PROTECTION FROM ANY LAW OR PATENT TO BE INFERRED. ALL PATENT RIGHTS ARE RESERVED. THE EXCLUSIVE REMEDY FOR ALL PROVEN CLAIMS IS REPLACEMENT OF OUR MA TERIALS AND IN NO EVENT SHALL Wf BE LIABLE FOR SPECIAL. INCIDENTAL OR CONSEQUENTIAL DAMAGES r\ RECOMMENDED MOLDING COMPOUNDS MOLDING POLYESTER CONDITIONS VJ Mold Conditions For best results, molds should be chrome plated, highly polished and free from stain. While non-chrome plated molds with textured finish have been used successfully, these conditions are not recommended. Type of Chrome _ A good hard chrome with a hardness of Rockwell C-60 applied over a well polished mold gives good results. Electroless nickle plating wears out very quickly unless it is specially heat treated. Undercuts Undercuts of 10 to 20 mils are suggested. The depth of undercuts will depend on the depth of draw, thickness of ribs and the amount of draft. Gates Gates for plunger and injection molding should be made as inserts so they can be replaced when worn. Mold Design Although unsurpassed electrically, thermoset polyesters do not have as much hot strength as other thermosetting molding compounds. For this reason, wherever possible the best results will be obtained by (1) Maximum allowable draft, generally not less than 2 degrees; (2) Numerous and about 25% larger than normal knockout pins; (3) Knockout pins with flats ground in them to allow air to escape and to prevent air entrapment, especially in deadend areas. In plunger and injection molds, most air entrapment occurs in the part of the mold opposite the gate and especially in the heaviest sections away from the gate; (4) Sharp edges and corners should be avoided. These should be rounded to a minimum radius of .010 to .020 mils wherever possible; (5) Full round runners and a well balanced runner system is recommended. Mold Shrinkage The shrinkage on Polylite polyester molding compounds as published can be adjusted within reasonable limits. Molds which have been designed for ureas, phenolics, melamines and BMC's can usually be used with Polylite polyesters. Quantity of Molds Since Polylite polyesters cure in about half the time of other thermosets, it is usually necessary to fabricate only half the number of molds required for ureas, etc. Conversely, existing molds can be run half the time for the same production or full time for double the production. .- Preforming Polylite polyester molding compounds preform exceptionably well. Most granulations are 4 mesh. If this is too coarse for small preforms, a finer granulation can be supplied. 0000128 See Reverse Side MOLDING COMPOUNDS POLYESTER RECOMMENDED MOLDING CONDITIONS (con't.) Types of Preheaters Flat bed preheaters are very acceptable. Electrodes should be. close together with an aluminum plate covering the preforms to make preheat more uniform. Preforms should be square or rectangular and placed on their edges to give the most uniform preheat. Preforms should be close together to prevent non-uniform preheating from air gaps. Rotisserie preheaters -- a larger size preheater is required than would be needed fora flat bed.This type preheater gives excellent results. Because of the uniformity of preheating hot or cold spots are prevented, resulting in more consistency in molding and usually faster cures. This type preheater must be larger because electrodes are further apart than in flat bed preheaters and excessively long preheat time, say over 30 seconds, is undesirable. Extruder type preheaters -- excellent results have been obtained with this type but only when the size of the extruded preform covers a minimum of 75% of the mold area. It is recommended that this type preheater not be used for circuit breakers. Cold powder is far superior and can usually be used without much loss in cure speed. Preform Transfer Time and Temperature Preforms should be transferred from the preheater to the compression mold or the plunger pot in no more than 10 seconds. Polyesters are very fast curing and cannot be handled in a casual fashion. Preform temperatures range from 170 to 200 F. 180 F is recommended. Smoking preforms should not be delivered to the mold since they are at least partially cured and could result in mold damage. Preforms do not get soft and mushy as do phenolics. At 170 F, preforms feel hard and only slightly pliable. At 200 F, preforms are soft but not mushy. Mold Temperature . Mold temperature of 300-350F are recommended although temperatures as high as 405F have been and are being used. Mold temperatures below 300 F greatly slow down cure and the free radical initiation which causes the unsaturation in the monomer and resin to react to polymerize the molecules and make cure result. The recommended starting mold temperature is 325 25 F. Higher temperatures will, of course, result in faster cures. The only limitation to increase in temperature is heavy flash, porosity (assuming the charge weight is ample) or precure. Precure shows itself as graying of the part with a black compound. If this occurs, mold temperature should be decreased 5-10 F at a time until the graying is eliminated. C000129 fX RECOMMENDED MOLDING COMPOUNDS MOLDING POLYESTER CONDITIONS V J(con't.) Molding Pressures Compression -- 3000 psi minimum to 6000 psi based on the projected mold area. Higher pressures combined with the stiffest flow at which flash cutoff can be obtained will result in the densest molding with the best electrical and mechanical properties, lowest shrinkage, fastest cure and least tendency to warp. Degas or Breathing Mold -- Polyesters are too fast curing to permit degas andmone should be used. Transfer and Injection -- Generally uses about 75% of maximum for first stage injection, then dropping to a holding or second stage pressure about half of first stage. Clamping pressures should always be maximum. Volume (speed) control can be used to adjust the closing time. Infection Molding -- Injection pressure (see above). Back pressure -- This should be kept at a minimum. 50 psig is ample to ensure uniform shot size. Polyesters should not be advanced in the barrel by increasing the back pressure as is done with other thermosets. Polyesters should remain thermoplastic in the cylinder. Curing takes place in the mold. Cylinder Temperature 180 F front and back is recommended. If extrudate is white, it indicates precure from too high a cylinder temperature, too high a screw speed or a worn screw. Screw speed -- 50 to 75 rpm. Deep flighted screws, 3/8" rather than 3/16", are desirable. Injection Time Best results are usually obtained by using the fastest injection speed. This is needed to fill the mold before the material cures. Polyesters do not generate gas or steam as do other thermosets, e.g., ammonia and steam with phenolics, formaldehyde and steam with ureas, etc. Nor do polyesters generate steam since the moisture content is zero. Trapping air is the main problem with injection molding of polyesters. Venting is extremely important, especially in deadend areas and thick sections furthest away from the gate. Mold Lubrication * Molds should not be lubrica ted, especially with Carnauba Wax or grease. Lubricants greatly decrease the hot strength of polyesters and can actually cause pieces to stick in the mold. Polylite polyesters can be molded directly after two-stage phenolics, ureas, melamines and BMC's. After one-step phenolics, a few shots of melamine should be run first. . OC00130 See Reverse Side r "\ RECOMMENDED MOLDING COMPOUNDS POLYESTER MOLDING CONDITIONS (con't.) Cure Time Polyesters have less hot strength than other thermosets. With ureas, melamines and phenolics, hot rigidity or hot strength on discharge from the mold can be improved by increasing the cure time. The opposite is true for polyesters. Hot strength on polyesters is improved by decreasing the cure time if the cure time is excessively longer than the minimum cure. When substituting polyesters for other thermosets, the cure should be decreased by 25% at the beginning and gradually decreased until a blister occurs. This will generally occur at a point 40 to 60% shorter than the cure ued for other thermosets. If there is a question as to whether or not a part is cured with polyesters, if there is no blister, the part is cured. Additional cure will add nothing to finished part properties. Most favorable results with Polylite polyesters are obtained with fast moving presses. S Reichhold Chemicals, Inc. P. O. Box 38, Middlesex Avenue Carteret, N. J. 07008 (201) 541-4201 0000131