PROCESSING DATA SHEET PC/ABS AUTOMOTIVE

PRODUCT LIST

MABLEX 273 - 274 - 280 STANDARD GRADES

MABLEX 273F - 274F - 280F HIGHER FLOW VERSIONS
MABLEX 274FB MAXIMUM FLOWABILITY
MABLEX 274LG LOW GLOSS
MABLEX 273HI HIGH IMPACT GRADE
MABLEX C274 TITANUIM DIOXIDE FILLED GRADE

MATERIAL DESCRIPTION

MABLEX™200 series is a PC/ABS blend designed for injection molding applications with a
good balance of mechanical and thermal properties. Thanks to its composition,
MABLEX™200 can be easily used in automotive applications where reduced gloss values
are generally required

DRYING

PC/ABS resins are hygroscopic; they absorb water from direct immersion and from humid air.
The amount of water absorbed normally depends on the exposure time, the air temperature
and the relative humidity.
At the temperatures used to mold PC/ABS, moisture levels can cause visual flaws and also
brittleness of the molded part.
Therefore, it is recommended that resin moisture content be limited to 0.05% when
processing MABLEX™ resins.

DRIYNG EQUIPMENT AND CONDITIONS

Hopper dryers that incorporate dehumidifying units are recommended for drying PC/ABS
resin granules. It is recommended 3-4 hours at 100°C as minimum-drying conditions for
PC/ABS resins dried in dehumidifying dryers. Closed hot-air systems are not recommended
for use. If tray dryers are used, the depth of the granules should not exceed 25 mm, and the
granules should be heated at 110°C for at least 4 to 6 hours, depending on the granule size.
Because dried granules of PC/ABS resin can quickly pick up moisture from the air, it is good
practice to use them as soon as possible after drying.

MACHINE SELECTION

The size of the machine to be used is determined by the volume of plastic required to fill the
mold cavity. It is
good practice to keep the shot size of the machine between 20 and 75 percent of the total
capacity. An optimum shot size is between 40 and 60 percent of the machine capacity.
There are three general guidelines for selection of the screw for an injection molding machine
to be used with PC/ABS resins:
1. A minimum of 15:1 length-to diameter ratio.
2. A compression ratio between 1.5:1 and 3.0:1.
3. Use of a slip-ring type non-return valve with clearances of at least 3.2 mm and a ring
movement of at least 4.8 mm.
 PROCESSING DATA SHEET PC/ABS AUTOMOTIVE

MELT TEMPERATURE

The molding machine should be set up to deliver a melt temperature between 250 to 270°C,
with an aim of 260°C. The optimum temperature profile depends on many variables such as
the ratio of machine capacity to shot size, screw design, mold and part design, and cycle
time. Reverse temperature profiles are used occasionally to compensate for improper screw
design, to reduce machine amperage or torque requirements, and to compensate for
machines with short L/D ratios.
Keeping a uniform melt temperature within recommended range is essential to ensure part
performance and color matching to mating component parts. Melt temperatures in the upper
end of the recommended range may be necessary when processing thin wall parts, difficult-
to-fill parts, parts with very small gates, and parts with long flow lengths. Excessive melt
temperatures may result in thermal degradation and a loss of performance, properties and
aesthetics. Lower processing temperatures reduce the risk of thermal degradation and
shorten the necessary cooling time. However, excessively low melt temperatures may result
in high residual molded-in stress.

MOLD TEMPERATURE

The mold temperature range recommended for PC/ABS materials is 50 to 80°C. Cooling time
is important for part performance and cycle time optimization. Using a mold temperature
controller will minimize temperature variations. Higher mold temperatures in the upper
recommended range generally provide better surface finish, less molded-in stress because of
slower cooling, and easier filling of thin wall parts and parts with long flow lengths. Lower
mold temperatures allow the molten polymer to set up faster to reduce the overall cycle time.
MABLEX™200 resins with different melt flow rates have different processing windows. In
general, resins having higher melt flow rates allow the use of lower mold and melt
temperatures. The higher melt flow rates are easier to process and their lower molding
temperatures allow for shorter cycle times.

PARAMETER VALUE

Barrel Temperatures :
Rear (Hopper) 225-240°C ; Intermediate 240-260°C ; Front 260-270°C ; Nozzle 250-260°C

Mold Temperature : 50-80°C

Pressure :
Back Pressure 3.0-15 Bar
Injection Pressure Adjust to control part weight & dimensions
Hold/Pack Pressure 30-70 Bar
Cushion 3.0-6.0 mm

Rate : Injection Speed Adjust to control appearance

Plasticizing Conditions :
A moderate screw speed of 40-70 RPM is recommended for MABLEX™200 resins.
 PROCESSING DATA SHEET PC/ABS AUTOMOTIVE

Injection Conditions : the appropriate injection speed for MABLEX™200 resins is

determined largely by gate design. PC/ABS resins are susceptible to formation of gate blush.
For parts gated into a visible surface it may be necessary to run the machine at as slow an
injection speed as possible.
During the packing phase, the material in the cavity is shrinking; to compensate for this
shrinkage, additional material must be supplied to the cavity until gates freeze-off. A small
melt cushion provides a ready source of additional melt to use during packing.
If the screw is allowed to "bottomout," the packing pressure cannot be transferred through the
polymer to pack out the cavity. This will result in poor part consistency due to short shots,
poor dimensional stability, excessive sink marks or poor aesthetics.
It is generally recommended that a small cushion size be employed to minimize heat history
on the polymer, reducing the potential for polymer degradation.

REGRIND

Regrind can be used with MABLEX™200 resins if care is taken to avoid cross contamination
and moisture pick-up; like virgin resin, regrind must be dried. Large particle sizes of regrind
may require longer drying times. However, parts that were rejected because they were
molded with wet resin or degraded parts cannot be regrind and reused.

PURGING

Where exposure time at a high temperature will, or has been excessive it may be necessary
to purge the barrel and nozzle. Purging will also be necessary for color or polymer changes.
There are many purging
compounds available on the market.
Purge at the low end of the melt processing range being careful not to exceed the screw
torque limit.
Alternatively a low melt flow rate GPPS or PMMA resin may be used.

Emission May 2007