LCP-007 VectraLCPProcessMoldDesignPPT AM 1013

Injection Molding Vectra® Liquid Crystal Polymers (LCP) Processing and Mold Design

© 2013 Celanese LCP-007 AM 10/13

Celanese Maintains Leading Position in Engineered Materials

Service temperature

Engineering Polymers

High-Performance Polymers (HPP) (TI1 > 150°C)

Engineering Polymers (ETP) (TI1 90 – 150°C)

Basic Polymers

LCP

– Vectra® /Zenite®

PPS

– Fortron®

PCT

– Thermx®

PET

– Impet®

PBT

– Celanex®

PBT Alloy

– Vandar®

TPC-ET

– Riteflex®

POM

– Hostaform®/Celcon®

UHMW-PE

– GUR®

Long Fiber and Continuous Fiber Reinforced Thermoplastics*

Amorphous

LFRT

– Celstran®, Factor ® Compel®

CFR-TP

– Celstran® Tapes, Rods and Profiles

Partially crystalline

TI1 = Temperature Index * with Matrix Polymers: PP, PA, PPS, PBT, POM and others on request © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Liquid Crystal Polymers are Very Unique

► Melting range rather than sharp melt point and very low heat

of fusion. ► High chain continuity, ordered molecular structure in both solid and melt phase. ► Flows extremely well under shear within the melting range. ► Inherently flame resistant. ► High heat deflection temperatures. ► Reinforcement reduced anisotropy increases load bearing capability.

© 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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LCP vs Semi-Crystalline Polymer Vectra® LCP maintains same molecular order in both the melt and solid phase. Nematic Liquid Crystal

Random Coil Melt

Extrusion

Solid State Extended chain Structure ► High Chain Continuity ► High Mechanical Properties ► Inherent Property Anisotropy © 2013 Celanese LCP-007 AM 10/13

Lamellar Structure ► Low Chain Continuity ► Lower Mechanical Properties

Vectra® Liquid Crystal Polymers (LCP)

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Vectra® LCP– A History of Innovation 340 S resin (S135)

HDT@ 1.8 MPa, °C

320 300

T resin (T130) 280

J resin (30% GF)

Ei resin (E130i) 260 C resin (C130) 240 A resin (A130)

L resin (L130)

220 200 1980

1985

1990

1995

2000

2005

2010

Continuous Innovation to Meet Customer Needs © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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The Heat Deflection Temperature vs. Tm 30-35% Glass Reinforced Grades Reflow Peak Temp

350

DTUL/A @ 1.8 MPa

330 310 290

Vectra S135

PPA

270

PPS

Vectra E130i

PA HTN PA 46

250

Reflow Peak Temp

PCT

Vectra A130

230 210 240

260

280

300

320

340

360

380

Melting Temperature °C

Reflow Peak Temperature is a Big Factor for Part Failure © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Vectra® LCP Products Fillers and reinforcements – to match performance with application needs

Filler Reinforcement

Effect(s)

Fiberglass

Stiffness and strength

Carbon fiber

Enhanced stiffness and strength

Mixed fillers/fibers

Wear resistance and stiffness

Mineral fillers

Flatness and surface appearance

Graphite flake

Wear and chemical resistance

Carbon black

Electrostatic dissipation

Proprietary fillers

Improved platability

Pigments

Color concentrates

© 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Vectra® LCP Grades Glass Fiber

A115 A130 A150

Carbon Fiber

A230 D3

Fiber / Filler

A430 FDA A435 FDA

E130i E150i E480i E130G

S135

E440i E 463i /E471i E473i E488i

S471 S475

E540i

Mineral Graphite

A625

Conductive

A700 A725 A230-D3

J540

S540 S625

E820i Pd E830i Pd E840i LDS

Plateable

Unreinforced

A950

LCP Alloy Blend

V140

V143 XL V143 LC

HDT Increases © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Spiral Flow vs. Other Resins (30-40% GF)

Vectra E130i PPS PCT PPA PET FR

0

50

100

150

Spiral Flow (Inches) Each molded at manufacturer’s recommended conditions and three injection pressures normalized to 30K psi. Cavity thickness = 0.125 in.

High Flow = Thinner Walls and Complex Parts © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Dimensional Stability

Stable dimensions after exposure to surface mount technology temperatures (reflow soldering) ► Change of length vs. 4.149-inch tool dimension ► SIMM molded at manufacturer’s recommended conditions ► SMT simulated by hot oil bath exposure at 260°C 4.5 SHRINKAGE (mils/inch)

4

As molded SMT @ 260°C

3.5 3 2.5 2 1.5 1 0.5 0 Vectra E130i

PPS 40GF

PPS 40GF HF PPA 33GF V0

HTN 35GF V0

Dimensional Variations Can Cause Contact Failure © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Water Absorption

Cross section of blistering sample (connector housing)

Water Absorption (ppm)

40000

LCP GF30

35000

Water Absorption (ppm)

LCP GF30

PPS GF40

PA9T GF33

PA9T GF33

PA6TGF30

PA46 GF40

30000 25000 20000 15000 10000 5000 0

40000

PPS GF40

PA6TGF30

20

40

PA46 GF40

60 Time (hours)

80

100

Condition: 60°C; 95%RH

35000 30000 25000 20000 15000 10000 5000 0 20

40

60

80

Time (hours)

Condition: 35°C; 85%RH

100

PA 6T GF30FR PA 46 GF30FR Condition: 40°C; 95%RH; 96 hrs; IR Reflow @ 265°C

High Water Absorption + Temp = Quality and Reliability Problems © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Automotive E&E Technology

MID/LDS

High Performance Connectors

LCP

Cookware

Electronic Packaging

Medical Tech Fibers

© 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Challenges on Materials for Interconnects Trends in Interconnects

Typical Design for Interconnects

Lead-free soldering (ROHS and WEEE)

Material Requirements Higher heat resistance High flow Improved flatness

Miniaturization (complex, thinner)

Stronger weldlines Higher frequency Electrical properties V-0 Halogen free

© 2013 Celanese LCP-007 AM 10/13

Agency compliance

Vectra® Liquid Crystal Polymers (LCP)

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Challenges in Materials for Electronics Halogen-Free Materials Elimination of Halogen Flame Retardants

Must Have Both Properties

High Temperature Halogen-Free Polymers

Increased Thermal Stability to Meet Lead-Free Soldering Requirements

Lead-Free Soldering Process RoHS and WEEE © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Molding

Processing Recommendations ► Drying ► General Processing Guidelines ► Equipment ► Additional Considerations

© 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Molding Drying Conditions ► LCP resins must be dried before molding to reduce the possibility

of hydrolytic degradation. ► Dry LCP at 150 - 170°C for a minimum of 6 hours; overnight

drying of LCP is preferred. Drying for up to 24 hours is acceptable and will not harm LCP. ► A dehumidified hopper dryer must be capable of maintaining

-40°C dew point. Insure that filter element is clean and there is good air flow (>1 ft/sec. space velocity across the surface of pellets). Hopper dryers with dual desiccant cartridges (one active while the other is regenerated) are highly recommended for all grades.

High Performance Applications Require Attention to Details © 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Molding Processing Temperatures

Processing Temperatures in °C 1 2 3 4 D M W1, W2

A Series

Ei Series

S Series

270 to 280

315 to 325

330 to 350

275 to 285

315 to 325

340 to 360

280 to 290

325 to 335

345 to 365

285 to 295

335 to 345

355 to 370

290 to 300

335 to 345

355 to 370

285 to 295

335 to 345

360 to 370

80 to 120

80 to 120

80 to 120

Note: Processing conditions for V143XL / LC same as for Ei series

© 2013 Celanese LCP-007 AM 10/13

Vectra® Liquid Crystal Polymers (LCP)

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Molding Molding Variables – Injection Pressure. Molding by position transfer or pressure transfer is preferred using high injection speed. Data acquisition equipment and pressure transducers in the tool to monitor process is recommended "E130i Lot 1HMV"

Lot 2 "E130i"

Typical processing conditions Max. residence time in barrel

If possible