ELECTRICAL & ELECTRONIC | MATERIALS
Another quite new grade, Durethan AKV30FN-
04LT, based on PA66, is optimised for laser trans- mission welding, a process increasingly used for joining electrical and electronic assemblies, since the process applies a low thermal load on the area around the weld and it is dust-free. Polyplastics highlights its expanding range of
laser-weldable PBTs. The Japanese company says it offers an extensive range in its Duranex family to facilitate laser welding of housing components for E&E and automotive applications. It says it has optimised the family by re-examining the rubber content, together with its compounding agents, to develop DuranexPBT 730LW which enables laser welding of workpieces as thick as 2mm – some- thing not possible with a predecessor material. Also emphasizing laser welding is DuPont. It says Schneider Electric, a global leader in energy management and automation, selected a new halogen-free and UL certified self-extinguishable grade of a Zytel PA66/6T, FR95G25V0NH, for a high dielectric strength housing for the high precision current sensor in its new connected Masterpact MTZ circuit breaker. The two companies worked together on developing this solution, which combines laser-weldability with long term aging performance – over 20 years (see also IW Nov/Dec 2017). Last year, SABIC announced Lexan HF4010SR polycarbonate for headlamp bezels, a grade that enables the production of complex designs with
enhanced aesthetics, it said. The company has also added new grades to its Lexan XHT line, with improved flow at high temperatures.
LED lighting
SABIC says the new materials come at a time when the complexity of forward lighting systems contin- ues to increase. “Current high-end LED headlamps weigh close to 6 kg with up to 200 components, thanks to the additional functionality they incorpo- rate,” it says. “Automakers are also striving to create highly distinctive lighting parts to help differentiate and increase the appeal of their vehicles.” When designing injection moulded parts, a low
draft angle is important because it enables greater styling freedom as well as a larger optical surface. However, the lower this angle, the more problems arise with parts sticking in the mould, creating scuff marks and potentially even resulting in a part with cosmetic defects. Lexan HF4010SR allows for draft angles between 0.5° and 1.0° lower than the recommended draft angle for PC tools (typically between 3° and 5°).
Bezels made in the new material can be metal- lized without the need for priming and gloss and reflectivity performance under high temperature environments are both very good. Parts perform in environments requiring a maximum constant use temperature of up to 130°C.
Above: This sensor case is laser welded in a 30% glass reinforced PBT developed by Polyplastics
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High-temperature polycarbonate for sensors and phone lenses
SABIC recently unveiled a line of high-clarity, high-heat, injection mouldable polycarbonate copolymer resins, Lexan CXT. They are said to offer a unique balance of high temperature resistance, high flow and excellent colour stability under extreme moulding conditions, together with a high refractive index. Typical target products include lenses and small sensors
that detect visible light. With Vicat B120 softening tempera- tures as high as 190°C and glass transition temperatures (Tg) of up to 195°C, the new resins withstand temperatures found in cold reflow and wave soldering used to attach components to printed circuit boards. Parts will also stand up to prolonged exposure to high service temperatures. Lexan CXT resins can have a refractive index (RI) over 1.6 as well as high transparency (greater than 89% in the visible and infrared spectra at a thickness of 1 mm), enabling production of very small lenses such as those used in mobile phones.
www.injectionworld.com
Lexan CXT resins are suitable for the tiny lenses on mobile phones that have taken the place of compact cameras, such is their ability to capture high-quality images
March 2018 | INJECTION WORLD 33
PHOTO: SABIC
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