lcp-009 zenitelcpoverviewppt am 1013 - celanese materials... · 2014-01-27 · zenite® lcp product...
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Zenite® LCP Overview
► LCPs and Zenite LCP► Zenite LCP Specific Properties► Products and Roadmap► UL Considerations► Comparative Data
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 2
LCP- Lyotropic or Thermotropic
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 3
Lyotropic►Very high melt point (~ 700°C)
> Decomposition temperature►Processed only in solution►High intermolecular forces►DuPont Kevlar®
Thermotropic►Melting point 200°C to 400°C►Melt processable►Weaker intermolecular forces►Vectra® / Zenite® LCP
General Attributes of Thermotropic LCP’s
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 4
Melt
Stress
Solid State
Even in the melt, LCPs are aligned in small regions… like uncooked spaghetti. The polymer chains further align and “slip” over each other as they flow into the runner and part. Since they are already oriented when they stop flowing, there is very little heat of fusion (freezing) so the resins sets up very fast!
Liquid CrystalPolymer Resins
ConventionalSemi-Crystalline Resins
Comparison of Amorphous Polymers vs. Semi-Crystalline Polymers. Where do LCP’s fit?
Amorphous Polymers Semi-Crystalline Polymers Liquid Crystal Polymers
No sharp melting point / soften gradually
Relatively sharp melting point Melt over a range of temperature; low heat of fusion which is about 5-10% of Semi-Crystalline resins
Random chain orientation in both solid and melt phase
Ordered arrangement of molecular chains and regular recurrence of crystalline structure only in solid phase
High chain continuity; extremely ordered molecular structure in both melt phase and solid phase
Do not flow as easily as semi-crystalline polymers
Flow easily above melting point Flow extremely well under shear above melting point yet tend not to flash due to fast freeze rate. Will flow even below “melt point” due to partial chain melting
Fiber glass and/or mineral reinforcement only slightly improves HDT
Reinforcement increases HDT considerably
Reinforcement reduces anisotropy and increases HDT
Can give transparent parts Part is usually opaque due to the crystal structure of semi-crystalline resin
Part is always opaque due to the crystal structure of LCP
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 5
Why do Customers use LCP’s?
►Very fast cycle times►High short-term temperature resistance►High long-term temperature resistance ‒ RTI up to 240°C
►Dimensional stability (Essentially no moisture absorption)►Very high flow without propensity to flash‒ Sections down to 0.15 mm
►Low Coefficient of Thermal Expansion (Flow direction esp.)►Inherently flame resistant…no added flame retardants ‒ Halogen and phosphorous free
►Extremely low out-gassing
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 6
Customer Benefit
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 7
Property Benefit
High flow Extreme miniaturization
High thermal resistance Lead-free re-flow solderingHigh temperature applications
High dielectric strength at high temperature (200°C)
Thin walls, insulation in high temperature applications
High dimensional stability Very high precision parts
Intrinsically UL94 V-0 No need for halogens, compliance with RoHS, WEEE
High chemical resistance Higher temperature chemical exposure
Compounding versatility Enables compounding technology to enhance specific properties
High gas barrier, etc. Low permeation
Zenite® LCP Property Retention vs. Heat and Time
Impact Strength
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 9
Zenite RTI tends to be in the 220°C to 240°C range when tested. Based on approximately 50% property retention at ~ 60,000 hrs.
Tensile Strength
Tem
pera
ture
(ºC
)
200
220
240
260
280
300
320
340
360
5000 6000 7000 7700HT
Heat Deflection Temperature of 30% GFMelt Point
Melt Point and HDT Comparison Zenite® LCP
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 10
Mechanical Properties Anisotropy of LCPs
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 11
Properties Most Affected►Mechanical►CLTE (coefficient of
linear thermal expansion)►ShrinkageProperties Least Affected►Electrical►Thermal ►Flammability►Chemical / barrier
In-flow direction 0.8 mm
Cross-flow direction 0.8 mm
In-flow direction 3.2 mm
Zenite® 6130L0
20406080
100120140160180
Gate
165150
50
Tens
ile S
treng
th [M
Pa]
Thinner Walls Improve Strength and Stiffness Through Greater Orientation
Zenite® 6130 BK010
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 12
Tensile Strength versus Temperature, ISO 527
Zenite® 6130 BK010
Tensile Modulus versus Temperature, ISO 527
HDT 1,8 MPa (°C )
61306330 7130
245°C 268°C 275°C 295°C 310°C
Elongation at Break (%)
7130 6130 6330
0.9% 1.7% 1.8% 3.5% 4.0%
Flex Modulus (GPa)
714561306330 7130
9.6 GPa 12.0 GPa 13.1 GPa 13.8 GPa
5130
5130L
Zenite® LCP Key Features
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 13
7145
7145L
Typical Fillers Used in Zenite® LCP
►Chopped Glass Fiber ►Milled Glass►Mineral►Fluoropolymers►Carbon Fiber/Carbon Black►Tougheners
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 15
Zenite® LCP Product Line Summary
Description Grade Filler Level Additional AttributesGeneral Purpose
6130L 30% glass reinforced, lubricated Standard grade7130 30% glass reinforced High deflection temperature
Improved Toughness
6330 30% mineral reinforced Improved surface and toughness5130L 30% glass reinforced, lubricated Very high flow5145L 45% glass reinforced, lubricated High flow and toughness
Improved Weldline 5145L 45% glass reinforced, lubricated High flow and toughnessReduced Warpage 7244 40% glass/mineral reinforced Increased flow, high temperature resistance
5244L 40% glass/mineral reinforced, lubricated Increased flow5145L 45% glass reinforced, lubricated High flow and toughnessZE55201 50% glass/mineral reinforced Lowest warpage
High Stiffness 7145L 45% glass reinforced, lubricated High deflection temperatureFood Grade FG6330 30% mineral reinforced Improved toughness Improved Wear & Friction ZE16401 30% mineral reinforced with PTFE Reduced warpageHigh Dielectric Constant ZE55205 45% glass/mineral reinforced Physical properties near standard glass gradesHigh CTI 7223 25% glass/mineral reinforced CTI UL PLC rating of 2 (250 up to 399 volts)High Flow 5145L 45% glass reinforced, lubricated Improved toughness, low warpage
5130L 30% glass reinforced, lubricated Improved toughness5115L 15% glass reinforced, lubricated Low Dk, temperature resistance
Improved Temperature Resistance
7145L 45% glass reinforced, lubricated High stiffness7130 30% glass reinforced Improved toughnessZE16130A 30% glass reinforced Improved adhesion (epoxy)7755 55% glass/mineral reinforced High HDT, low warpage
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 16
Zenite® LCP Resin Attributes… Road Map
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 17
Improved Toughness
ReducedWarpage
63305130L5145L
72445244L
ZE55201
72445145L5130L5115L
7145L7130
ImprovedTemperatureResistance
Higher Flow
Temp.Resist
Highest
6130LX6130L
Epoxy Adhesion
ZE16130AHigh Dk
ZE55205
Specialty
Temp.Resist
Highest
UL Insulation SystemsLong Term Aging using Motorette’s to allow prequalification of resins used as magnet wire support for motors and transformers.
© 2013 Celanese LCP-009 AM 10/13
UL EIS Related Applications
►Coil winding bobbins/inductors/chokes requiring long term thermal exposure
►Coil winding bobbins/inductor/choke required to sustain Pb-free SMT soldering
►Motors slot insulation
Value Proposition of Product offering –► 6130 (L) – standard offer► 7130 – when 6130 cannot meet temperature requirement► 5130L/5145L – when higher elongation/weld line strength is
needed
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 21
UL Status –Insulation Systems by Thermal Class
Grade 130°C 155°C 180°C 200°C 220°C
5130L LZ100 LZ200
5145L LZ100 LZ200
6130(L) LR130 L200(N, JX)L201 (N)
L301, T301 (N)
RL410 L500(N)
7130 LZ100 L200(N, JX)L201 (N),
LZ200
RL410 L500(N)
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 22
UL End-Product Standards that Refer to UL1446 for Product Selection Criteria(These products need to have pretested EIS at UL ahead of Product testing)
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 23
UL1446 Electrical Insulation System
► UL60950-1 Information Technology Equipment► UL60335-1 Safety of Household & Similar Electrical Appliances► UL1411 Transformers and Motor Transformers► UL1585 Class 2&3 Transformers► UL60065 Audio-, Video- and similar Electronic Apparatus► UL1004 Electric Motors► UL508 Industrial Control Equipments► UL906 Solenoids► UL429 Electrically Operated Valves► UL935 Fluorescent Lamp Ballasts
UL1446 EIS Extension Opportunity
► Other product test standards have the same test process‒ IEEE 117 Low voltage windings (<1KV) for Automotive
‒ IEC 61857 EIS – Procedure of thermal evaluation – low voltage(<1KV) – Electrotechnical products
► Product Agencies that also recognize UL1446 (avoid duplicate testing) –CSA, BSI, JIS, Intertek (but not vice versa)
► New emerging applications ‒ Alternative Energy (Photo Voltaics/Inverters)
‒ Electrical Vehicle
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 24
UL1446 Electrical Insulation System
Knit Line StrengthRelative Resistance to Fracture Using a Pin Insertion Test
© 2013 Celanese LCP-009 AM 10/13
Knit Line Strength
►Using double gated tensile bar and “picture frame” flexural sample
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 26
Cut this area for knit line strength testing
Flexural ModeTensile Mode
Comparison DataKnit Line Strength (Flexural Mode)
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 27
Max
Min
0
20
40
60
80
100
6130L 5115L 5130L 5145L 5244L
0.4mmt Weld Flexural Strength
0.000.200.400.600.801.001.201.401.60
6130L 5115L 5130L 5145L 5244L
0.4mmt Weld Flexural Max Strain
Comparison DataWeld Strength (Tensile Mode)
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 28
0.0
5.0
10.0
15.0
20.0
25.0
30.0
6130L 5115L 5130L 5145L 5244L
0.8mmt Weld Flexural Strength
0.00
0.05
0.10
0.15
0.20
0.25
6130L 5115L 5130L 5145L 5244L
0.8mmt Weld Flexural Max Strain
Max
Min
IR Reflow Result
Condition Moisture(%) 240°C 250°C 265°C 280°C
Zenite 6130DAM 0.011
Wet 0.095
Zenite 7130DAM 0.012
Wet 0.089
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 30
Generally better HDT’s result in improved blistering resistance at the same conditions
No Problem A little discoloration or deformation
Discoloration or deformation or 1 blistering in 5
Comparison Data – 0.2mmt Flow
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 32
349°C
Flow (mm)* At recommended processing temperature
11.5
11.6
12.9
15
16.6
18
18.9
0 5 10 15 20
5145L
7130*
5244L
5130L
ZE17235*
7225*
5115L
349°C
349°C
349°C
Exposure to SMT Temperatures causes additional Shrinkage especially in Cross Flow (Normal) Shrinkage
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 34
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
Zenite 6130 L BK010
Zenite 7145L BK010
Change in Shrinkage
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 35
Shrinkage during SMT is primarily cross flow which tends to increase and raise the total stress in the part.
Normal – Parallel Shrinkageafter molding
Normal – Parallel Shrinkageafter annealing
Increased in Normal – Parallel Shrinkage after annealing
% S
hrin
kage
As Molded
After Annealing at 250°C, 1 Hr
Change after Annealing. Increase in differential can lead
to increased stress and warpage
Warpage
Empirical Data from Several Resin Families
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 36
Calculated Warpage
In General, Warpage tends to be non-linear with shrinkage differential and the stiffer the sample, the less warpage for the same differential shrinkage, eg., 3mm disks tend to warp less than 0.8mm disks molded from the same resin.
Warpage – 1.6mm x 100mm
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 37
3.764.6
5.2
7.287.85
5.45.83
7.97
10.29 10.01
0
2
4
6
8
10
12
5244L 6130L 5145L 5130L 5115L
War
page
(mm
)
DAM260C X 5min
Laser Marking
Laser Systems Tested► Nd: YAG at 1.06 micron wavelength (NIR), beam deflection method with 200-500
mm/s writing speed, pulsed (ca 10 ns pulses with repetition rates from 1 kHz to 20 kHz), maximum average power 60 W
► Nd:YAG at 532 nm wavelength (VIS), beam deflection method with 200 mm/s writing speed, pulsed (ca10 ns pulses with repetition rates from 1 kHz to 20 kHz), maximum average power 10 W
► Excimer laser at 248 nm wavelength (UV, projection method, pulsed, each pulse with 145 mJ/cm2, 5 pulses exposure
► Excimer laser at 193 nm wavelength (UV), mask projection method, pulsed, each pulse with 25 mJ/cm2, 3 pulses exposure
Results
© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 39
Laser Wavelength 6130 BK010 6130 WT010 6130L BK010 7130 BK010 7130 WT010
Pulsed Nd: YAG Laser 1064 nm Visible Visible Visible Visible Visible
Pulsed Nd:YAG Laser 532 nm Not Tested Not Tested Not Tested Visible Visible
Pulsed Excimer Laser 248 nm Hardly Visible Hardly Visible Hardly Visible Hardly Visible Hardly Visible
Pulsed Excimer Laser 193 nm No Effect Visible No Effect No Effect Visible
DisclaimerThis publication was printed on 1 October, 2013 based on Celanese’s present state of knowledge, and Celanese undertakes no obligation to update it. Because conditions of product use are outside Celanese’s control, Celanese makes no warranties, express or implied, and assumes no liability in connection with any use of this information. Nothing herein is intended as a license to operate under or a recommendation to infringe any patents.
Copyright © 2013 Celanese or its affiliates. All rights reserved.
Contact Information
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© 2013 Celanese LCP-009 AM 10/13 Zenite® LCP 40