Specialty Film & sheet

Lexan*, Valox* and Ultem* Films

Technical Manual

sharing our futures

Index
13 pt praxis light

introduction 5

Products 6

Lexan Film Polished Grades 7

Lexan Film Textured Grades 7
Lexan Film Flame Retardant Grades 7
Valox Film 8
Ultem Film 8
Lexan High Performance Grades 9
Surface Texture Guide 9
A Choice of Masking Materials 1

Typical Properties 11

Physical Properties 12

Optical Properties 13

Mechanical Properties 15

Thermal Properties 17

Electrical Properties 18

Environmental Properties 21

Flammability 23

Processing 25

SABIC Innovative Plastics 3

Introduction

SABIC Innovative Plastics Specialty Film and Sheet

manufactures engineering film products for a
wide range of industries and users, including
graphic screenprinting, In Mold Decoration,
weatherable applications and high temperature
electric applications, among others.

Application and product development activities are

conducted at SABIC Innovative Plastics’ company
headquarters in Pittsfield, Massachusetts, USA, the
European headquarters in Bergen op Zoom, the Net-
herlands, andt he China Technology Center in Shanghai,
China. It is here, in our state-of-the-art laboratories, that
printing, forming, trimming, and injection molding ma-
chinery makes it possible for our engineers, designers
and technologists to explore and extend the boundaries
of film application development and In-Mold Surface
technology for our customers.

Around the globe, SABIC Innovative Plastics Specialty

Film and Sheet delivers value to customers through
innovative products, superior customer responsiveness
and hands-on technical assistance.

SABIC Innovative Plastics 5

Products

High Performance Engineering Thermoplastic Film

for Electrical, Electronic, Industrial and Consumer Applications

Lexan polycarbonate films offer an unusual combination Because of their excellent property profile plus
of features including clarity, dimensional stability, processing strengths, Lexan films have proven
toughness, flexibility, heat resistance, and excellent outstanding in many areas. Electrical characteristics, in
dielectric performance. The versatile performance and addition to temperature and dimensional stability, flame
fabricating features of these SABIC-IP products suggest resistance and toughness, make Lexan films the logical
a variety of applications including nameplates, cable choice for electrical applications.
wrapping, automotive instrument clusters, membrane
switch overlays, metallized films, and many others. In graphic applications, Lexan films are widely used
because they permit printing by various methods:
Virtually haze free, with proven qualities for superior screen printing, hot stamping, flexographic, litho,
performance, Lexan films meet requirements for the full rotogravure, vacuum metallization without
spectrum of film applications. Superior tear strength pretreatment, and digital printing. Lexan films can also
compared to other films is a practical plus which be formed by various methods: embossing,
translates into fewer rejects, fewer production/handling hydroforming, pressure forming, contact heat pressure
problems, higher quality, and more durable products. forming, pressure assist forming, and thermoforming.
The combination of ease of printing, forming, and the
The versatility of Lexan films enables the user to handle ability to get clean cuts with steel rule or matched
a wide range of jobs on conventional equipment where metal trim dies makes Lexan films an excellent choice
special grades or additional processing techniques may for the insert material in In Mold Decoration. Learn
be needed with other films. Information on how to use more at www.sabic-ip.com/imd.
our products in IMD applications can be found at
www.sabic-ip.com/imd.

6 SABIC Innovative Plastics

Lexan* Film Polished Grades Flame Retardant Grades
Lexan polished films offer 86% to 92% light transmis- The family of Sabic Innovative Plastics Flame Retardant
sion through all gauges, from 5 to 30 mil (0.125 to (FR) films is UL94 listed and offers a range of surface
0.750 mm). This makes them the ideal choice for LED/ textures and properties.
LCD windows and for applications where second surface
printing is desirable, such as fascia panels for house- These films meet stringent requirements for a wide
hold appliances, audio/video equipment and automo- range of electrical and electronic applications. Polished
tive dials. Custom colors and optical quality films are and textured films are available in this family of films.
available. Lexan films with both surfaces polished can They can be easily fabricated with conventional conver-
be formed through various techniques and/or selecti- ting equipment including forming, embossing, and steel
vely textured by screen printing for aesthetic purposes. rule die creasing and/or cutting. All FR films offered by
Screen printing can also provide a mar-resistant finish. Sabic-IP hold their shape when bent which allows for
Standard grades are available specifically for use with ease of assembly compared to other films. They are
conventional solvent based inks as well as UV cured inks. also well suited for lamination which provides flexibility
The following is a partial list of some of the polished film to combine shielding and insulation in a single part.
options with a smooth high gloss surface on both sides:
UL file number: E121562USA/E103380NDL
Lexan 8010 film – our standard offering
Lexan T2FOQ film – an optical quality version of 8010 Potential applications include:
with less inclusions, improved forming consistency, • power supply insulation
and improved gauge control • disc drive insulation
Lexan 8020 film – custom colored • bus bar insulation
Lexan DMX 1HD00 – a coex product with a 1H • TV/monitor insulation
hardness polycarbonate layer • PC board insulation
Lexan SLX 11010 – an excellent choice when chemical • business equipment insulation
resistance or outdoor weathering is needed • keyboard insulation
• speaker covers
• foil lamination for insulation and shielding
Lexan Film Textured Grades • menu boards
Lexan textured film grades offer a wide range of bene- • high voltage internal insulation
fits. First surface textures are anti-reflective and control • high-temperature PSA tapes
light diffusion. Textured films are easy to process and • motor slot-liners and wedges
can also be formed. They allow for “deadfront” graphics • transformer wraps
for illuminated instruction or warning lights. In addition, • layer and phase insulation
textured first surfaces help to conceal scratches. Clear • speaker cones
windows can be wet out using screen printed inks for
applications that require a combination of texture and The following is a partial list the flame retardant grades
polish. Textured films are suitable for a broad range available:
of applications including automotive dials, audio/video FR60 - Polish/polish transparent FR film
remote control fascias, labels for industrial equipment, FR63 - Polish/matte transparent FR film
control panels for HVAC and office equipment. FR65 - Matte/velvet transparent FR film
FR700 - Fine matte/velvet black FR film
Lexan polycarbonate films come in various combinati- FR25A - Polish/velvet colored FR film
ons of textures for customised design flexibility. These (Colors include White, black)
textures offer:
• excellent scratch resistance
• an ideal fit for light-emitting devices (LEDs)
• low gloss levels

The following is a partial list of some of the textured

films offered:
Lexan 8B35 – Velvet texture on one side with a matte
texture on the other
Lexan 8A13 – Polished on one side with a matte
texture on the other
Lexan 8A35 – Polished on one side with velvet texture
on the other
Lexan SD8B14 – a tight tolerance one side velvet/one
side fine matte film for overlay or intermediate layers in
security card applications
Lexan SD8B24 – a white version of SD8B14 with
excellent opacity to hide security devices in security
card applications
Lexan SD8B94 – a laser markable version of SD8B14

SABIC Innovative Plastics 7

Environmental Friendly Noryl* EFR735 Film
Flame Retardant Film EFR 735 is halogen-free flame retardant Polyphenylene
The family of Sabic Innovative Plastics environmental Oxide film offering UL94 VTM-0 performance down
friendly FR films is UL94 listed and offers a range of to 0.006” (152 microns) and excellent temperature
surface textures and properties to cover the current performance to meet the requirements in a wide range
electrical and electronic (EE) flame retardant (FR) of electrical, electronic and transportation applications.
brominated polycarbonate (PC) film markets with UL94 EFR 735 film has outstanding dielectric strength, ease of
VTM-0/V-0 listing at 0.1~0.51 mm. These films have fabrication such as thermoforming, embossing, clean-
formability, excellent mechanical properties, good edge die-cutting, score and bend. Gauges available are
dimensional stability at high temperatures and a high 6mil, 10mil, 17mil and 25mil in Matte/Velvet texture
flammability rating, making it good for applications such finish.
as power supply insulation, disc drive insulation, bus-bar
insulation, TV/monitor insulation, PC board insulation, UL file number: E121562USA
business equipment insulation and has insulation and
EMI/RFI shielding when laminated with metal foil. Potential applications include:
• power supply insulation
The following is a partial list of some of the textured • TV/monitor insulation
films offered: • PC board insulation
Lexan* EFR65 - Nature/Black Velvet texture on one side • business equipment insulation
with a matte texture on the other • keyboard insulation
Lexan* EFR63 - Nature color fine matte texture on one • high voltage internal insulation
side with a polish on the other • layer and phase insulation
Lexan* EFR95 - Black only, Velvet texture on one side • speaker cones
with a fine matte texture on the other

UL file number: E205960 Ultem* Film

Ultem* 1000 film is a high performance thermoplastic
polyetherimide material. The combination of Class H
Valox* Film high temperature resistance, low moisture absorption
Valox* FR 1 film is a flame retarded polybutylene and excellent dielectric properties makes Ultem 1000
terephthalate material offering good temperature film a popular choice for a broad range of electrical/
resistance, excellent dielectric strength, and ease of electronic applications, including:
fabrication. Valox FR1 offers flame retarded UL94 VTM-0
performance down to 0.125 mm. This material has • high voltage internal insulation
found use in a wide range of applications in the electro- • high-temperature PSA tapes
nics and graphics industries. Applications include disc • motor slot-liners and wedges
drive insulation, business equipment components requi- • transformer wraps
ring barrier insulation, and menu boards. With its low • layer and phase insulation
moisture absorption and excellent chemical resistance, • speaker cones
it is commonly used for laminated EMI/RFI shields.
Ultem 1000 film is thermoformable and can be heat
UL file number: E121562USA/E103380NDL sealed to a wide variety of metals and thermoplastics.

Potential applications include:

•power supply insulation
• disc drive insulation
• bus bar insulation
• keyboard insulation
• TV/monitor insulation
• PC board insulation
• business equipment insulation
• foil lamination for insulation and shielding
• menu boards

8 SABIC Innovative Plastics

Lexan Film High Performance Grades (HP) Surface Texture Guide
Chemical and abrasion resistant grades Polished:
Lexan High Performance films offer exceptional resistan- Virtually defect-free. Excellent printing surface with true
ce to attack by chemicals and to abrasion, making them ink color fidelity and optics. Particularly effective for
suitable for a wide range of applications, including flat LED/LCD windows. Provides primary substrate finish for
membrane switches, anti-reflective computer screens screener-applied selective textures.
and display windows for audio/video equipment, cell
phone and hand held device lenses, washing machine Fine matt:
and microwave oven control panels. Good printing surface, not as smooth as polished.

HPxxH grades are suitable for second surface printing Matt:

only and offer optimum abrasion resistance. HPxxS Light diffuser. Hides filaments and eliminates
grades are suitable for printing on both surfaces, ”hot spots” in back-lit applications. Preferable finish for
using UV curing ink on the coated side. Both series are deadfront graphics. Offers reduced surface reflection
available in grades which provide varying gloss levels for and gloss.
application-specific tailoring. 92, 60, 40, and 12 gloss
levels are available. Velvet:
Hides scratches, fingerprints and marring for heavy-use
Chemical, abrasion and UV resistant grades applications. Also acts as a diffuser for ”windowed” or
(HP92W, HP12W, and HP92X) back-lit applications.
Lexan High Performance Weatherable films feature a
proprietary UV-stable coating, which brings long-lasting Suede:
outdoor performance to a wide range of graphics ap- Excellent in very heavy-wear applications.
plications including: warning labels for garden equip- Resists abrasion while maintaining its attractive
ment, signage, gas pump point of purchase, and marine appearance.
graphics.

Abrasion and Fog resistant grades

Lexan High Performance Formable Anti Fog (HPFAF) film
offers anti fog performance and anti static perfor-
mance. It is available in custom colors and is well suited
for sport goggle applications and gauges.

Lexan HP92AF film combines the anti fog performance

of HPFAF with the abrasion and chemical resistance of
HP92S. This product has an anti fog coating on one
side and an abrasion resistant coating on the other side.
It is useful in medical face shields, goggles, and other
applications.

Lexan High Performance Freezer Door Film (HPFDF)

combines anti frost performance on one side of the film
with an optical adhesive on the other side of the film.
This combination along with an NSF splash zone rating
make Lexan HPFDF an excellent candidate for applicati-
on on the reach in freezer cases found in super markets
and convenience stores.

SABIC Innovative Plastics 9

A Choice of Masking Materials HP films are available with maskings (on both sides).
Polished Lexan films like Lexan 80xx films are available Typically cling masking is applied on the coated side
with a choice masking materials: while a variety of different maskings are applied de-
Stick, a masking with pressure-sensitive adhesive, pending on the gloss (texture) of the coated side. An
applied for use when rough handling is expected example is the Y mask, a coextruded masking available
during processing or shipping. This can be used for for 92 gloss HP films which prevents an increase in tack
applications requiring thermoforming, pressure forming level due to age or processing even after up to 20 pas-
or other forming operations where it is desirable. ses of solvent or UV ink printing.
Cling, a static-applied masking material for easy
removal.

Masking is not available for textured film products.

Table 1a: Masking information for uncoated films Table 1b: Masking information for uncoated films

Designation Top Mask Bottom Masking Top (Coated) Bottom (Uncoated)

Designation
Mask Masking
A NO MASK STICK
B (HP12, HP40, HP60) STICK TRUE-CLING
C TRUE-CLING STICK D (HP12, HP40) NO-MASK TRUE-CLING
E TRUE-CLING TRUE-CLING Y (HP92) COEX TRUE-CLING
MD DD Cling 1 side MD DD Cling 1 side
ME DE Cling 2 sides ME DE Cling 2 sides
MS DS Cling/Joggable Mask
MS DS Cling/Joggable Mask

Remarks
• Masking is required on all gauges Lexan 8010/FR60

10 SABIC Innovative Plastics

Typical Properties

Table 2: Typical Properties

Lexan
Polished/ Lexan FR HP Valox Ultem
Textured
Property Test Unit Value+ Value+ Value+ Value+ Value+
Physical
Specific Gravity DIN 53479 1.20 1.32 1.20 1.34 1.27
Water Absorption, 24 hours ASTM D570 % change 0.35 0.28 0.35 0.48 0.48
Pencil Hardness ASTM D3363 - B B HB-F B B
Pencil Hardness ASTM D3363 - B B HB B B
Optical
Haze ASTM D1003 % 0.4 Polished 0.6 Polished 0.5 Polished 103 white n.a.
Light Transmission ASTM D1003 % 91 91 92 15 n.a.
Refractive index, 25°C ASTM D524A - 1.6 1.6 1.5 n.a. n.a.
Mechanical
Tensile Strength ASTM D882
at yield psi (MPa) 8,500 (60) 10,000 (70) 8,500 (60) 7200 (50) 14,500 (100)
at break psi (MPa) 9,000 (65) 8,500 (60) 8,500 (60) 6000 (41) 13,800 (95)
Elongation at break ASTM D882 % 100 25 100 150 50
Tensile Modulus ASTM D882 psi (Mpa) 300000 (2500) 319000 (2200) 305000 (2100) 277000 (1900) 421000 (2900)
Tear Strength
Initiation ASTM D1004 lb/mil (kN/m) 1.4 (245) 1.7 (298) 1.4 (245) 1.5 (250) 2.2 (365)
Propagation ASTM D1922 g/mil (kN/m) 30-55 (10-20) 20 (6) 40 (14) 54 (20) 25 (8)
Coefficient of static friction ASTM D1894 - - - - 0.39 0.72
Coefficient of kinetic friction ASTM D1894 - - - - 0.35 0.65
Poisson’s ratio ASTM D132-61 - 0.38 0.38 0.38 0.38 0.42
Thermal
Shrinkage at 302˚F (150˚C) ASTM D1204 % 1.4 0.9 1.4 0.4 0.33 {170˚C}
DTUL, @ 264 psi (1.8 N/mm2) ASTM D648 °F (°C) 290 (145) 290 (145) 290 (145) 174 (79) 392 (200)
Vicat Softening Temperature, B ASTM D1525 °F (°C) 320 (160) 347 (175) 320 (160) 346 (174) 419 (215)
Glass Transition Temperature ASTM D3417/D3418 °F (°C) 307 (153) 307 (153) 307 (153) 183 (84) 422 (217)
Coefficient of Thermal Expansion ASTM E831 x 10-5 /°F (x 10-5 /°C) 3.2 (5.8) 3.2 (5.8) 3.2 (5.8) 3.1 (5.7) 2.7 (5.0)
Thermal Conductivity ASTM D5470 Btu/hr/ft2/°F /in 1.35 1.35 1.35 1.35 1.49
(W/m.°K) (0.20) (0.20) (0.20) (0.2) (0.22)
Brittleness Temperature ASTM D746 °F (°C) -211 (-135) -211 (-135) -211 (-135) -211 (-135) n.a.
Electrical
Dielectric Strength, 23°C,
kV/mil
10 mil (0.25mm) ASTM D149 1.81 (71) 1.5 (59) - 1.09 (43) 5 (197)
(kV/mm)
in oil, short time
Dielectric Constant ASTM D150
at 60 KHz 2.32 2.9 - 3.31 3.2
at 1 KHz 2.3 2.8 - 3.26 3.2
at 1 MHz 2.3 2.8 - 2.8 3.2
Dissipation factor ASTM D150
at 60 Hz 0.001 0.0026 - 0.0015 na
at 1 KHZ - 0.0028 - 0.004 0.004
at 1 MHz 0.006 0.0117 - 0.010 0.005
Volume Resistivity ASTM D257 Ohm-cm 8.65 E +16 1 E+17 - 1 E+17 2.5 E+15
Surface Resistivity ASTM D257 Ohm/square 5.24 E+15 1 E+16 - 1 E+16 1.9 E +16
Arc Resistance, Tungsten ASTM D495 s 70 64 - 21 54
Flammability•
Oxygen index ASTM D2683 % 25 33 25 30 47
UL Flammability UL94 VTM-2, 0.075 mm VTM-0, 0.075 mm HB 0.25 mm VTM-2, 0.075 mm VTM-0, 0.025 mm
V-2, 0.250 mm V-0, 0.250 mm VTM-0, 0.127 mm

•
These ratings are not intended to reflect hazards presented by this or any other material under actual fire conditions. n.a. not applicable

SABIC Innovative Plastics 11

Physical Properties
13 pt praxis light

Density/specific gravity Water absorption/moisture

Physical Properties The determination of water absorption by a plastic
Density and specific gravity are often used interchange- specimen of defined dimensions is carried out by im-
ably, which is technically incorrect. The difference is the mersion in water for a specified time and at a specified
following: density is mass per unit volume of a material temperature. The measured results are expressed in
at 73°F (23°C); specific gravity is the mass of a given either milligrams’ absorbed water or as a percentage
volume of material at 73°F (23°C) divided by an equal increase in weight.
volume of water at the same temperature. The con-
version is: density (kg/m3) = specific gravity x 0.99756. All SABIC Innovative Plastics Specialty Film and Sheet’s
The often used term “relative density” has the same films show very low water absorption. The moisture
meaning as “specific gravity”. These values are used to content may result in changes in dimensions or in pro-
determine the area factor, or the amount of coverage perties such as electrical insulation resistance, dielectric
for a given thickness. losses, mechanical strength and appearance.

Table 3: Specific gravity

Lexan Lexan FR Valox Ultem

1.20 1.32 1.34 1.27

In a formula this reads:

Area factor in m2/kg = 1 / (spec. gravity x thickness (mm))

Convert to ft2/lb by multiplying the Area factor in m2/kg by 4.8816.

So for a 10 mil (0.254 mm) stardard Lexan film the approximate

coverage is 3.28 m2/kg or 16.0 ft2/lb.

12 SABIC Innovative Plastics

Optical Properties
13 pt praxis light

1. Light Transmission
Lexan films’ optical properties are important for graphic Refractive Index
and packaging applications. High light transmission and A light beam is transmitted through a transparent 2. Refractive Index
low haze values make Lexan film one of the highest cla- specimen at a certain angle. The deviation of the beam, 3. xxxxx
rity films available. In applications where optical quality caused when the light passes through the specimen, is
or low stress is important, Optical Quality or OQ grades the index of refraction, found by dividing sin α by sin β.
may be available. See figure 2.

Haze Gloss DIN 67350, ASTM D 523

Haze is a measurement of the amount of perpendicular Gloss is associated with the capacity of a surface to
light transmission lost due to scattering within the film. reflect more light in some directions than in others.
Haze contributes to difficulty in seeing objects clearly Gloss can be measured in a glossmeter. A bright light is
through the film and muting of second-surface printed reflected off a specimen at an angle and the luminance
inks. Lexan polished film’s low haze levels ensure clarity or brightness of the reflected beam is measured by a
and excellent color of second-surface inks. photodetector. Most commonly, a 60° angle is used.
Polished materials can be measured at 20° and matte
surfaces at 85°. The angle used may also depend on
Yellowness Index the intended use of the material. The glossmeter is
Yellowness Index (YI) is a measurement of the deviation calibrated by using a black glass standard with a gloss
from whiteness (waterwhiteness) of the film in simu- value of 100. See figure 3.
lated daylight illumination relative to a white standard
(magnesium oxide). Low YI values prevent color changes Table 4: Gardner Gloss Levels After Screenprinting Flat
of white and pastel inks printed on the second surface Black (Min.- Max.)
of the film. Special Lexan film products with controlled
YI are available. Please contact your local film distributor Film Angle Velvet Matt Suede
for more information.
8B35 60° 3.0-4.5 5.0-15.0
8B36 60° 3.0-12.0 0.0-2.0
Light Transmission 8A13 85° 4.0-10.0
As shown in Graph 1, most Lexan films transmit 90%
8A35 60° 8.0-14.0
of visible light and are somewhat opaque to ultraviolet
light. This helps to protect second-surface graphics,
package contents and the film itself from degradation
caused by ultraviolet radiation from the sun an floures-
cent lighting. Long-term, direct solar exposure, however,
is not recommended without additional protection to
reduce chalking of the film surface. Custom colors and
grades are available to block or transmit more or less
light at specified wavelengths.

100
90
Lexan 8040 Film
80
Transmission (%)

Non-UV
70
60
50
Lexan 8010 Film
40
UV stabilised
30
20
10
0
275 300 325 350 375 400 500 600 700 780 1000 1500 2000 2500 3000 3500
UV Visible Wave length (nm) Near infra-red
1

α Specimen

specimen Source Lens Receptor Lens

Collector Lens
60°

Photodetector
Source
β

2 3

SABIC Innovative Plastics 13

Table 5:

Property Test Method Units Typical Values

HP92W

HP12W
HP92H

HP60H

HP40H

HP12H

HP92X
HP92S

HP60S

HP40S

HP12S
Gloss-Backpainted ASTM D523 Gardner
Flat Black
60° 89 62 34 10 92 62 40 12 92 12 92
85° - - 66 38 - - 45 - - -
20° 84 - - - - - - - 80 16 80
Gloss-Clear Over ASTM D523 Gardner
White
60° 167 103 60 25 165 103 64 27 165 24 165
85° - - 65 43 - - - 45 - - -
20° 179 - - - 181 - - - 160 105 160

Light Diffusion Half Value Angle

Light diffusion in accordance with DIN 5036 is a measu- This is the angle at which only half of the transmitted
rement of the amount of perpendicular light transmis- light is measured against the 90 degrees luminous
sion lost due to scattering of light. Light diffusion is transmittance.
measured when haze measurement becomes unreliable
(>35%). Textures and special filter systems are used to
improve light diffusion.

Table 6: Light diffusion of Lexan film Table 7: Half value angle of Lexan film

Polished Texture Filled Polished Texture Filled

0.00 0.04 0.06 0° 3° 6°

14 SABIC Innovative Plastics

Mechanical Properties
13 pt praxis light

4. Typical Stress-Strain curve

Tensile strength, elongation and modulus are properties These properties are important in pressure-sensitive
that describe the behaviour of the film in tension. tape applications and whenever the film is processed
At room temperature, typical values for SABIC Innovative in roll form.
Plastics Specialty Film and Sheet’s film are:

Table 8:

Unit Lexan Lexan FR Valox Ultem

Tensile strength at yield psi (N/mm2) 9000 (62) 10100 (70) 7200 (50) 16000 (110)
Tensile strength at break psi (N/mm2) 9400 (65) 8700 (60) 6000 (41) 1700 (115)
Elongation break % 100 100 57 60
Tensile modulus kpsi (N/mm )
2
304 (2100) 319(2200) 275 (1900) 363 (2500)

Stress-strain Tear Strength

Stress-strain curves illustrate the ability to withstand The tear resistance of a film is the force needed to
short-term loading. A typical curve with general initiate and propagate a tear. The stress is recorded
definitions is shown in figure 4 and tear inititiation and propagation resistance is
normally expressed in pound force or Newtons. The
Stresses can be accurately predicted by using basic tear resistance can also be expressed in force per unit
mechanical engineering equations. These equations, of thickness, although comparisons between dissimilar
based on Hookes Law, apply to the linear portion of the materials and/or thicknesses may not be valid. The tear
stress-strain diagram below the proportional resistance measured in accordance with ASTM D1004/
(elastic) limit. ASTM D1925 is shown below.

Hookes Law states that stress is directly proportional to Table 9:

strain, and is expressed as:
Tear initiation Tear propagation
σ Material
E = ____ (D1004) lb/mil (kN/m) (D1925) g/mil (kN/m)
ε Lexan 1.4 – 1.8 (245 – 298) 30 – 55 (10 - 20)
Where: σ = Stress, psi (N/mm )2 Valox 1.46 (250) 55 (20)
E = Modulus of elasticity, psi ( N/mm2) Ultem 2.1 (365) 24 (8)
ε = Elongation, mm/mm

Like most thermoplastics, Lexan, Valox, and Ultem exhi-

bit a spring-like behaviour when loaded in tension below Fold Endurance
the proportional limit. This means that the film will When tested on the M.I.T. fold endurance tests Lexan
stretch and return to its original dimension as tension Film varies widely with gauge. One-mil (25 micron) film
is applied and removed. When printing or die cutting will survive about 12,000 double folds; 5 mil (125 mi-
from a web in tension, it may be important to consider cron) 500 double folds; and 10 mil (250 micron) 200 folds.
this dimensional change.

The following formula can be used to compensate for Frictional Characteristics

this behaviour to ensure accurate registration: The smooth surface of Valox film makes it appropriate
in load bearing surface applications. Valox film also
ε =
F
AxE
has very low coefficients of static and dynamic friction
against metal. The coefficient of static friction of Valox
film is 0.39 measured in accordance with ASTM D1894.
Where ε = Strain (stretch in inches (mm),
per inch (mm) of web)
F = Web tension in pounds (N) ultimate force Fmax
force at break Lb
A = Cross-sectional area of web in squar inches yield force Fy
(mm2) (width x thickness)
E = Tensile modulus in psi ( N/mm2)

The value of “E” will change with temperature.

proportional limit
A corresponding necking down or decrease in web
width will occur. This can be quantified by using Pois-
son’s ratio, which is the ratio of transverse contraction
to elongation of a web under tension. For SABIC Innova- elongation at yield ∆ Ly
tive Plastics Specialty Film and Sheet’s film this number elongation at F max ∆ L f max
is 0.38. When multiplied by the strain in the previous
formula, this will give the decrease in web width. elongation at break ∆ Lb

SABIC Innovative Plastics 15

16 SABIC Innovative Plastics
Thermal Properties
13 pt praxis light

5. Tensile Modulus vs.

Tensile Heat Distortion, DTUL, Vicat Lexan films exhibit polycarbonate’s excellent resistance Temperature
Tensile heat distortion, DTUL and Vicat softening tempe- to oxidative embrittlement. After six months at 167°F
rature values give an indication of the heat performance (75°C) Lexan films showed no measureable change in
of plastics materials. They show the temperatures at tensile yield and ultimate tensile strength. The tensile
which a test specimen will deflect a given distance yield point and the ultimate tensile strength of the
under a given load in tension, flexure and compression samples tested increased some 10% during six months
under specified test conditions. The higher the reported at 257°F (125°C). However, the elongation of the same
value, the higher the material’s practical end-use tem- films dropped from an initial average of 97% to a final
perature is likely to be. elongation of 9%. It should be noted that none of the
film samples tested were brittle enough to crack by
All thermoplastics undergo mechanical property chan- creasing even after the six month aging period.
ges with changing temperature. Amorphous materials
such as Lexan polycarbonate change slowly and in an Degredation of optical properties (decreased light
almost linear fashion with increasing temperatures up transmission, increased haze and yellowness) can also
to 300°F (150°C), where the material begins to soften. occur after long-term exposure to high temperatures.
Softening continues until it melts at about 420°F (215
°C). Relative thermal stability of Lexan film to 300°F Lexan film should not be exposed on a continuous
(150°C) makes it a good candidate for high-tempera- basis to temperatures exceeding 185°F (85°C).
ture applications, and the wide softening range allows
ease in thermoforming. Following the screen printing Low temperatures have little effect on Lexan film, which
of Lexan film, drying temperatures as high as 120°C can remains ductile down to at least -150°F (-101°C).
be used.

Valox, being a crystalline thermoplastic polyester, shows Shrinkage

a more pronounced dependence on temperature. Ill. 5 Since Lexan and Ultem films are isotropic and amor-
illustrates tensile modulus as a function of temperature. phous, they are very dimensionally stable at elevated
temperatures. Exposure to temperatures as high as
275°F (135°C) for Lexan and 302°F (150°C) for Utem
RTI and effects of Heat Ageing for short periods (30 min.), results in no detectable
RTI, or Relative Thermal Index, is the continuous opera- change in dimension.
ting temperature of plastics materials used in electrical
applications, as tested by UL. Or “the maximum service Lexan film from 3 mil to 5 mil (0.075-0.125 mm) will
temperature at which the critical properties of a ma- shrink about 0.5% at 302°F (150°C). Heavier gauge
terial will remain within acceptable limits over a long film may shrink 1-2% at 302 oF (150°C) depending on
period of time”. The “end of service” life is defined as gauge. At temperatures above 302°F (150°C), theglass
the time at which a material property has degraded to transition temperature, dimensional changes become
50% of its original value after 100,000 hours’ continu- more pronounced with Lexan films.
ous exposure. RTI tests are important if the final product
is to receive UL recognition. RTI values for various Lexan When thermoforming, the shrinkage off of the forming
films are listed in Table 10. tools will vary somewhat depending on the thermofor-
ming tool temperature and cooling time on the tool.
Table 10: For Lexan the shrinkage will range from 0.8% to 0.9%.
Relative Thermal
index (°C)

Mechanical
Without Elong.
With Elong.
Thickness
Material

40
(tensile)
Colour

Elect.

Tensile Modulus (N/mm2 x 102)

Valox FR 1 nc 0.075-0.100 - - - 30
nc 0.125-0.225 125 120 120
nc 0.250-0.350 125 120 120
20
all 0.375-0.600 125 120 125
all >=0.635 120 120 140 Lexan
Lexan FR 6x cl 0.25-0.35 130 125 130 10
Valox
cl 0.375-0.74 130 125 130
cl >=0.750 130 125 130
0
Lexan FR 700 bk 0.25-0.35 130 125 130
0 23 60 90 100 120 150 180
bk 0.375-0.74 130 125 130
Temperature (°C)
bk >=0.750 130 125 130
5

SABIC Innovative Plastics 17

Electrical
13 pt praxisProperties
light

6. Dielectric Strength vs
SABIC Innovative Plastics Specialty Film and Sheet’s films Dielectric constant Material Thickness
are characterised by excellent dielectric properties. High Dielectric constant at 60 Hz ranges from about 2.95
7. xxx
dielectric strength and insulation resistance, together to 3.05 over the range of 32 - 257°F (0-125°C) for
with consistent dielectric loss values and superior arc all Lexan and Valox films. Ultem has a slightly higher
resistance, make them ideal materials for many applica- dielectric constant of 3.2 over the same range. Water 8. Effect of Frequency on the
Dielectric Constant at 73°F
tions in electronic and electrical components. absorption up to equilibrium does not affect this value (23°C)
appreciably.

Dielectric strength
SABIC Innovative Plastics Specialty Film and Sheet’s
film provides excellent resistance to breakdown in the
presence of high voltage AC stress. Table 11 shows the
relation of dielectric strength to material thickness as
tested according to ASTM D149. All films give similar
results and are virtually unaffected by humidity and
heat ageing. Absolute resistance to high voltage can be
determined by multiplying the dielectric strength in kV/
mil (kV/mm) by the material thickness in mils (mm).

Table 11: Dielectric Strength, ASTM D149, kV/mm

Gauge (mm) Lexan FR Valox Ultem

0.05 - - 6450
0.075 7550 9350 8100
0.1 9000 10800 9500
0.125 10300 12100 10800
0.175 12600 14300 13050
0.25 15650 17100 -
0.375 20050 21000 -
0.5 23850 24200 -
0.625 27300 27050 -
0.75 30500 29650 -

~ E ~ E

Lexan Film

Lexan Film

3.30

3.20
Ultem
Dielectric constant

3.10
Valox
Lexan
3.00
Ultem
2.90
Lexan FR
2.80

2.70
102 103 104 105 106 107 108 109 1010
Frequency (Hz)
8
18 SABIC Innovative Plastics
 9. xxx
Dissipation Factor Volume/Surface Resistivity
Values for dielectric loss, i.e., dissipation or power Lexan films exhibit high resistance to DC current both 10. Variation of Dissipation
Factor with Temperature
factors, are essentially the same across the Lexan film through and across the surface of the film. Both water (at 60 Hz), Lexan
range. From room temperature to 212°F (100°C), the absorption up to equilibrium and heat ageing have a
factor is approximately 0.001 (0.1%). It increases gra- negligible effect on these properties. 11. Effect of Frequency on the
Dissipation Factor at 23°C
dually to 0.002 at 284°F (140°C) and increases sharply
beyond 302°F (150°C). Fig 11 illustrates the effect of 12.
frequency on the dissipation factor. Arc Resistance 13. Effect of Temperature on
Resistance to high voltage arcing across the film surface the Volume Resistivity of
varies somewhat with the type of film. Non-flame-retar- Lexan
ded grades such as Lexan 8010 generally have better 14. xxx
resistance to arc breakdown than the flame-retarded
grades.

~ E
+
Lexan Film

Lexan Film

R
Volume

-
+ - Lexan Film

Surface
2
12
% 1

0 16
10
Volume Resistivity (Ohm.m)

-25 0 25 50 75 100 125 150

Temperature (°C) 15
10
10 14
10

1.2 13
10
1.1 Lexan FR
Valox
1.0 12
10
Dissipation factor (%)

0.9
0.8 11
10
0.7 -50 -25 0 25 50 75 100 125 150
0.6 Lexan Temperature (°C)
0.5 Ultem
0.4 13
0.3
8.5 x 10 = 0.62%
9
0.2 2.5 x 1010 = 0.59%
0.1 E
0
102 103 104 105 106 107 108 109 1010
Frequency (Hz)
11
Lexan Film

14

SABIC Innovative Plastics 19

Performance Level Categories, PLC Table 15:
PLC, or Performance Level Categories, as defined by UL: PLC level
“In order to avoid an excessive level of implied precision High Current Arc PLC level
and bias, material performances for several tests are 120 ≤ NA 0
recorded as PLC, based on the mean test results (rather
60 ≤ NA < 120 1
than recording the exact numerical results)”. PLC levels
are assigned to electric properties, tested according to 30 ≤ NA < 60 2
UL746A. 15 ≤ NA < 30 3
Please refer to the following Tables: 0 ≤ NA < 15 4

Table 12: Ignition, HAI

NA - Number of Arcs
Performance
Level Categories
(PLCs) Table 16:
Thickness (mm)

H D
Hot Wire Ignition, HWI PLC level
H H V 4 C
Material

120 ≤ IT 0
Colour

W A T 9 T
60 ≤ IT < 120 1
I I R 5 I 30 ≤ IT < 60 2
Ultem 1000 nc 0.05 - - - 5 - 15 ≤ IT < 30 3
Valox FR 1 nc 0.075-0.100 - - 4 6 2 7 ≤ IT < 15 4
nc 0.125-0.225 - 4 6 2 2 0 ≤ IT < 7 5
nc 0.250-0.350 4 0 4 6 2
IT - Ignition Time in sec.
all 0.375-0.600 4 0 4 6 2
all >=0.635 3 0 3 6 2
Table 17:
Lexan FR 6x cl 0.25-0.35 1 0 - 6 3
cl 0.375-0.74 0 0 - 6 3 Arc Resistance, D495 PLC level
cl >=0.750 0 0 - 6 3 420 ≤ TAR 0
Lexan FR 700 bk 0.25-0.35 1 0 - - 3 360 ≤ TAR < 420 1
bk 0.375-0.74 0 0 - - 3 300 ≤ TAR < 360 2
240 ≤ TAR < 300 3
bk >=0.750 0 0 - - 3
180 ≤ TAR < 240 4
120 ≤ TAR < 180 5
Table 13:
60 ≤ TAR < 120 6

Comparative Tracking Index, CTI PLC level 0 ≤ TAR < 60 7

600 ≤ TI 0
TAR - Time of Arc Resistance in sec.
400 ≤ TI < 600 1
250 ≤ TI < 400 2
175 ≤ TI < 250 3
100 ≤ TI < 175 4
0 ≤ TI < 100 5

TI - Tracking Index in Volt

Table 14:

High Voltage Arc PLC level

0 ≤ TR < 10 0
10 ≤ TR < 25 1
25 ≤ TR < 80 2
80 ≤ TR < 150 3
150 ≤ TR 4

Tracking Rate, HVTR

TR - Tracking Rate in mm/min

20 SABIC Innovative Plastics

Environmental
13 pt praxis light Properties

Chemical Resistance Table 18: General Chemical Resistance Overview

At moderate temperatures and low stress levels, SABIC
Innovative Plastics Specialty Film and Sheet’s film is

Amorphous

-Crystalline
generally compatible with most substances encoun-

Lexan

Valox
Semi
tered in home or office environments. However, when Chemical
stressed in some manner such as by cold-forming,
flexing on embossing, some substances will cause the
Hydrocarbons
film to craze or stress-crack. Elevated temperatures can aliphatic -/• •
initiate or accelerate this type of degradation. aromatic - +
halogenated - fully •/+ -
Some organic chemicals such as acetone, toluene - partly - -
and halogenated hydrocarbons will act as solvents to Alcohols + +
SABIC Innovative Plastics Specialty Film and Sheet’s Phenols - nt
film. Methylene chloride, for example, is often used to Ketones - -
solvent-bond SABIC Innovative Plastics Specialty Film and Amides nt nt
Sheet’s films. Amines nt nt
Esters -/• -
A coated film should be used in applications where the- Ethers - nt
re is exposure to aggressive or incompatible substances. Acids
Tables 18 and 19 offer guide-lines on SABIC Innovative Inorganic - concentrated -/• •/+
Plastics Specialty Film and Sheet’s film’s compatibility - diluted • +
with general classes of chemicals. Testing is strongly Organic - concentrated • •/+
recommended when there may be a question of SABIC - diluted • +
Innovative Plastics Specialty Film and Sheet’s film’s resi- Oxidising - concentrated - •/+
stance to substances encountered in either processing - diluted + +
or end-use. Alkalis
concentrated - -
SABIC Innovative Plastics Specialty Film and Sheet will diluted - •
provide assistance in determining compatibility with Salts
specific substances. acids + +
neutral ++ +
alkali • +
Automotive fluids
greases (non-reactive organic esters) nt +
oils (unsaturated aliphatic mixtures) nt ++
waxes (heavy oils) nt +
gasoline - ++
cooling liquid (glycol) + ++
brake fluid (heavy alcohol) - ++
detergents, cleaners + +
Water hot -/• •
Rating: - = Poor •= Fair + = Good ++ = Excellent nt = not tested
Table 19: Chemical Resistance Lexan HP Films

Lexan HPXXS Film Results Lexan HP92W Film Results Lexan HPXXH Film Results
As Manufactured• Post Cured** As Manufactured• As Manufactured•
1 hr Continuous Surface 1 hr Continuous Surface Continuous Contact (23˚C)
Chemical Contact (23°C) Contact (23°C) One hour Three hours
Acetone Failed Passed Failed (40 - 45 min) Passed Failed***
MEK Failed Passed Failed (45 min) Passed Failed***
Toluene Failed Passed Passed Passed Failed***
Methylene Chloride Failed Passed Failed Passed Failed***
Isopropyl Alcohol Passed Passed Passed Passed Passed
Cyclohexanone Failed Passed Passed Passed Passed
Ethyl Acetate Failed Passed Passed Passed -
Xylene Failed Passed Passed Passed Passed
40% NaOH Failed Passed Passed Passed Passed
Concentrated HCI Passed Passed Passed Passed Passed
Gasoline (Regular) Passed Passed Passed Passed Passed
Gasoline (Unleaded) Passed Passed Passed Passed Passed
Butyl Cellulose Failed Passed Passed Passed Passed

•
Lexan HPXXS films can be printed on the hardcoated side.
** Post cure: One elliptical focused medium pressure mercury vapour lamp at 120 Watt/cm and a conveyor speed of 6 m/minute.
*** A few small Coating blisters.

SABIC Innovative Plastics 21

 15. QUV Accelerated
Effects of Water UV Resistance Weathering
No significant changes have been noted in tensile and Lexan HP92W and HP92X films utilize a proprietary coa- (ASTM G53 - UV313 BB)
elongation properties measured on films immersed in ting technology developed by SABIC Innovative Plastics. 16. Xenon Arc Accelerated
water for several weeks. However, boiling water immer- This special coating protects the film from yellowing Weathering
sion seriously and rapidly affects the elongation of Lexan and hazing, maintaining the appearance of the graphics
films. The tensile yield and ultimate tensile strength behind the film. With a yellowness index of less than 2.5
values do not change significantly. Long-term immer- at 1000 hours of QUV testing, Lexan HP92W film is a
sion in sea water at normal temperatures has no effect natural choice for demanding outdoor applications.
on Lexan film. Valox and Ultem films show an improved
performance over Lexan films. Lexan SLX 11010BC film is a clear film of 7 to 10 mil
thickness that may be used alone or in a backmol-
ded configuration to provide exceptional weathering,
Permeability good chemical and scratch resistance and outstanding
Plastic films often have specific resistance to gas and aesthetics for a wide variety of applications in automo-
moisture vapor passage, which is important in various tive, telecommunications and outdoor vehicles. It can
packaging applications. Permeability is a function of the be printed either first or second surface and retains
diffusion rate, the solubility of the gas in the barrier and good aesthetics and performance, even after significant
the barrier thickness. Table 20 gives gas and moisture outdoor exposure.
vapour permeability data for Lexan film at room tempe-
rature, gauge 10 mil (0.025 mm). Lexan GS133 film is a laminate of Poly Vinyl Floride (PVF)
and Lexan polycarbonate graphic film. With this lami-
nate technology, Lexan GS133 film offers high chemical
Weatherability resistance, formability, and long term resistance to
Long-term exposure to direct sunlight will cause outdoor weathering.
unprotected SABIC Innovative Plastics Specialty Film and
Sheet’s film to surface chalk (removable) and yellow.
The length of time before a noticeable change occurs
depends on the severity of the exposure and the thick-
ness of film, and can be anywhere from several months
to several years. Unprotected SABIC Innovative Plastics
Specialty Film and Sheet’s film is not recommended,
therefore, for outdoor applications where the retention
of aesthetics and mechanical properties is required. For
intermittent outdoor exposure or long-term exposure
to fluorescent lighting, all SABIC Innovative Plastics
Specialty Film and Sheet’s films will show excellent
performance.

Table 20: Permeability to Gas and Moisture

Lexan Unit
Air 85 (1340) ml/mil/100 in2/24 hr – atm (cc/m2 - 24 hrs – atm)
Nitrogen 50 (787) ml/mil/100 in2/24 hr – atm (cc/m2 - 24 hrs – atm)
Oxygen 300 (3500) ml/mil/100 in2/24 hr – atm (cc/m2 - 24 hrs – atm)
Carbon Dioxide 1075 (20000) ml/mil/100 in2/24 hr – atm (cc/m2 - 24 hrs – atm)
Moisture Vapour 8 (85) g/100 in2/24 hr – atm (cc/m2 - 24 hrs – atm)

15 20
18 HPxxH
Yellowness Index
Yellowness Index

12 16
Uncoated polycarbonate film 14
9 12
8010
10
6 8 Clear SLX
6
Lexan HP92W film 4
3 2.2YI
2 GS133
0 0
0 200 400 600 800 1000 0 1200 1500 1800 2100 3750
Time (Hours) Time (Hours)
15 16

22 SABIC Innovative Plastics

Flammability
13 pt praxis light

17. xx
Table 21:

Property** Test Lexan Lexan FR Valox Ultem

UL Flammability Bulletin 94 V-2, 0.250 mm V, 0.250 mm VTM-0, 0.127 mm VTM-0, 0.025 mm
- VTM-2, 0.125 mm VTM-0, 0.050 mm VTM-2, 0.080 mm -
Oxygen Index ASTM D2863 25 33 30 47
Flash Point - 454°C 440°C - -
Self-Ignition Temperature - 575°C 605°C - -
FMVSS 302 ISO 3792 pass >0.250 mm pass >0.250 mm pass >0.250 mm pass >0.250 mm
NFPA 258-NBS Smoke ASTM E662 D (4) = 17 D (4) = 6 - 0
Chamber
Test (.250 mm) - D (max) = 50 D (max) = 36 - 0
Horizontal Burn Rate ASTM D635 - - - -
Extent of Burn - 75 mm 36 mm - -
Burn Time - 65 sec. 5 sec. - -

** These tests and ratings are not intended to reflect hazards presented by this or any other material under actual fire conditions.
 pdated yellow cards for Sabic Innovative Plastics Specialty Film and Sheet products may be found at www.UL.com
** U
UL file number E61257 for the US and E103380 for Europe.

Compared to most other polymers, SABIC Innovative

Plastics Specialty Film and Sheet’s films are characteri-
sed by high inherent flammability resistance. As a result,
SABIC Innovative Plastics Specialty Film and Sheet’s films
are widely used in electrical/electronic, automotive
and construction applications. SABIC Innovative Plastics
Specialty Film and Sheet’sFR films are formulated to
provide further protection against burning and ignition, Pilot flame
as shown in Table 21.
Specimen

Limiting Oxygen Index ISO 4589

(ASTM D 2863)
The purpose of the oxygen index test is to measure the
relative flammability of materials by burning them in a
controlled environment. The oxygen index represents
the minimum level of oxygen in the atmosphere which
N2/02
can sustain flame on a thermoplastic material.
The test atmosphere is an externally controlled mixture
of nitrogen and oxygen with a pilot flame, which is then 17
removed. In successive test runs, the oxygen concentra-
tion is reduced to a point where the sample can no lon-
ger support combustion. Limiting Oxygen Index or LOI is
defined as the minimum oxygen concentration in which
the material will burn for three minutes, or can keep the
sample burning over a distance of 50 mm. The higher
the LOI value, the less the likelihood of combustion.

Table 22: Limiting Oxygen Index

Lexan Lexan FR Valox Ultem

25 33 30 47

SABIC Innovative Plastics 23

 13 pt praxis light

18. xxx
UL94 flammability in general Table 23:
The most widely accepted flammability performance 19. xxx
standards for plastic materials are UL94 ratings. These
are intended to identify a material’s ability to extinguish UL94 Flame
Material Color Thickness (mm)
Rating*
a flame, once ignited. Several ratings can be applied
based on the rate of burning, time to extinguish, ability Ultem 1000 NC 0.025 VTM-0
to resist dripping, and on whether the drips are burning.
Each material tested may receive several ratings based Valox FR 1 nc 0.08 VTM-2
on color and/or thickness. When specifying a material nc 0.127-0.51 VTM-0
for an application, the UL rating should be applicable Lexan FR 6/7 cl 0.05 VTM-0
for the thinnest wall section in the plastic part. The UL
rating should always be reported with the thickness: just cl/bk 0.13 VTM-0
reporting the UL rating without mentioning thickness is cl 0.25 V-0
insufficient.
** Not tested, generic value
Summary of the UL94 rating categories
HB- slow burning on a horizontal specimen UL94HB
Where flammability is a safety requirement, HB rated
burning rate < 76 mm/min for thickness < 3 mm materials are normally not permitted. In general,
HB classified materials are not recommended for electri-
burning rate < 38 mm/min for thickness > 3 mm cal applications except for mechanical and/or decora-
tive purposes. For applications such as plug housings,
V-0- burning stops within 10 seconds on a vertical requiring a high CTI, HB classified materials can be used.
specimen; no drips allowed
It should be stressed that non-FR materials, (or materials
V-1-burning stops within 30 seconds on a vertical that are not meant to be FR materials), do not automa-
specimen; no drips allowed tically meet HB requirements. Although the least severe,
UL94HB is a flammability classification and has to be
V-2- burning stops within 30 seconds on a vertical checked by testing.
specimen; drips of flaming particles are allowed
UL94V-0, V-1 and V-2
5V-burning stops within 60 seconds after five The vertical tests take the same specimens as are used
applications of a flame - larger than used in for the HB test. Burning times, glowing times and, when
V-testing - for 5 seconds on a test bar. dripping occurs, whether or not the cotton beneath
ignites, are all noted. Flaming drips - widely recognised
5VA- plaque specimens may not have a burn- as a main source for the spread of fire or flames - distin-
through (no hole) - highest UL rating guishes V-1 from V-2.

5VB- plaque specimens may have a burn-through

(have a hole);

VTM-0- this rating category applies to very thin gauge

materials. A cylindrical test specimen is used instead of
a test bar. The burning and dripping requirements are
comparable to the V test.

V0-2 test HB test

HB test 5V test 25.4 mm

76.2 mm
25.4 mm
Specimen
25.4 mm Specimen
76.2 mm 127 mm
25.4 mm 127
mm
Mark
40 m Mark
m
127 mm 19 mm
9.5 mm
Mark 45°

Mark
m

20°
45°

18 19

Test plaque

5VA and 5VB test

24 SABIC Innovative Plastics

Processing
13 pt praxis light

Printing Printing Inks Compatible with Lexan Film

Lexan polycarbonate film can be first (front) surface (as of 2009)
printed and, due to its excellent clarity at any gauge,
it is also ideal for second-surface printing. Most inks Table 24: Physical Solvent Drying Systems
adhere well to Lexan film without pretreatment or print
coat which many other plastic films require. Many prin- Manufacturers
ting techniques can be applied to Lexan films including
Akzo Nobel Coatings Inc. www.akzonobel.com
screenprinting, digital printing, sublimation printing,
offset printing, and flexographic printing. Coates / SunChemical www.sunchemical.com
JUJO Chemical Co., Ltd. www.jujo-chemical.co.jp
Many inks contain aggressive organic solvents that
Seiko Advance Ltd. www.seikoadvance.co.jp
promote adhesion to the film but may contribute to
film failure if not removed before further fabrication. Teikoku Printing Inks Mfg. www.teikokuink.com
Therefore it is suggested to thoroughly dry all inks Co., Ltd. www.teikokuink.com/en
after printing (preferably at elevated temperatures) to Naz-Dar Corporation www.nazdar.com
remove all solvents.
Visprox B.V. www.visprox.com
Tables 24 through 31 list manufacturers by ink system RUCO Druckfarben www.ruco.de
who carry products those manufacturers recommend ECKART www.eckart.net.html
for use on Lexan polycarbonate film. This list is by no
Pröll KG www.proell.de
means all-inclusive and could be subjected to change
resulting, for example, from changes in ink formulation Sericol Limited www.sericol.com
by the ink manufacturers. Particular care should be ta- Marabuwerke GmbH & Co. www.marabuwerke.de
ken in case the Lexan film is to be stressed or bent after www.marabu.com
printing. In all cases it is recommended to perform end-
use testing to determine compatibility with all materials
in the system. Table 25: Conductive Inks

Printing Tips Manufacturers

a. Use static eliminators to facilitate sheet handling
Acheson www.achesonindustries.com
and reduce dust attraction. (www.stopstatic.com)
www.achesonelectronicmaterials.com
b. Keep the printing press and area free of dust
and smoke.
c. Web processing - refer to Section, Mechanical
Properties, for web stretch information. Table 26: UV Curing Systems
d. Drive off solvents as soon as possible. Lexan film can
be safely dried at temperatures up to 250°F (120°C) Manufacturers
e. Make sure UV inks are formulated to cure completely
Coates / SunChemical www.sunchemical.com
according to your requirement.
/products.aspx
f. Follow guide-lines for offset printing on synthetic
materials; i.e. with low-solvent inks or thin ink film, ECKART www.eckart.net.html
increase alcohol content of dampening solution, use Visprox B.V. www.visprox.com
short lifts to prevent set-off, etc.
Sericol Limited www.sericol.com
g. Work with SABIC Innovative Plastics Specialty Film
and Sheet, your film converter, and ink supplier Polymeric Imaging Inc. www.polymericimaging.com/2/
for best results. Marabuwerke GmbH & Co. www.marabuwerke.de
www.marabu.com/
RUCO Druckfarben www.ruco.de/
Nor-Cote UK Limited www.norcote.com/

Table 27: Screen Print / Spray Protective Masking

Use a 1.5 to 2 mil (37 to 50 micron) thickness for ease
of removal. Apply over textures prior to forming to limit
the increase in gloss

Manufacturers
Kiwo www.kiwo.com
Spraylat www.spraylat.com/home.aspx

SABIC Innovative Plastics 25

Table 28: Coatings and Clear Varnish for Inks for 2nd Surface In Mold Decoration (IMD)
Abrasion/Chem Resistance Lexan polycarbonate film can be used in the In Mold
Decoration (IMD) process. If the inks will be 1st surface
Manufacturers printed then the ink systems found in tables 24 through
30 may be suitable if they meet the durability require-
Ernst Diegel GmbH www.diegel.de/
ments for the application. If the part will be a second
ECKART www.eckart.net.html surface IMD application then the ink will become
sandwiched between the injection molded resin and
the film that the ink is printed on. In this instance the
Table 29: Offset Printing Inks inks must be able to withstand the high thermal and
mechanical shear of the injected resin. Table 32 lists ink
Manufacturers systems that have been found to be compatible with
2nd Surface IMD.
Eastern Marking Machine www.easternmarking.com/ Learn more about IMD at www.sabic-ip.com/imd.
consumables.html#inks
Table 32: Inks compatible with 2nd surface In Mold
Table 30: Flexographic/Letterpress/Gravure Inks Decoration

Manufacturers Manufacturers Products

ECKART www.eckart.net.html Coates / SunChemical Decomold Ultrabond DMU
www.sunchemical.com *** only UV ink system that
Sicpa Sinclair www.sicpa.com
works without binders
Del-Val Ink & Color www.dvink.com
JUJO Chemical Co., Ltd. 3300 Series
Custom Printing Inks www.customprintinginks.com www.jujo-chemical.co.jp 3200 Series w/ G2S binder
Marabuwerke GmbH & Co. Maramold MPC
Table 31: Sublimation Inks www.marabuwerke.de/
www.marabu.com/
Manufacturers Naz-Dar Corporation 9600
www.nazdar.com 8400
Gans Inks www.gansink.com
Nor-Cote UK Limited MSK w/ Seiko binders
Apollo Colors www.apollocolors.com
www.norcote.com/ MSK w/ Proell Aquapress
Naz-Dar Corporation www.nazdar.com binder
Pröll KG N2K
www.proell.de Noriphan HTR
M1 and M2 mirror inks
Seiko Advance Ltd. KKS Super Slow Dry
www.seikoadvance.co.jp/ AKE (N) w/ N3A, JT10, or
JT20 binder
Teikoku Printing Inks Mfg. Co., Ltd. IPX series w/ IMB 003
www.teikokuink.com binder
www.teikokuink.com/en

26 SABIC Innovative Plastics

Digital Printing Table 33: Digital Ink Jet Printing Equipment Suppliers
Lexan polycarbonate film is compatible with digital
printing and in many instances can be printed on Supplier
directly with the digital printing machine without a
Vutek Inc. www.vutek.com
print receptive pre-treatment. Piezo-head technology
is the most popular technology and has been found to Oce www.oce.com
be the most compatible with Lexan film. It enables Inca www.incadigital.com
hot-melt inks to be used which solidifies immediately
Roland www.rolanddga.com
upon contact with the Lexan substrate. The figure
below shows a schematic of this technology. Mimaki www.mimakiusa.com
Mutoh www.mutoh.com
Table 33 lists several companies that manufacture UV
Lotte www.lotte.co.jp/english/
ink jet or solvent ink jet printing equipment capable
index.html
of direct printing on Lexan film. These suppliers offer
flat bed and/or roll fed options. Conditions for direct Gandinnovations www.gandinnovations.com
printing on Lexan film will vary from one printer to the HP Scitex Industrial Printers www.hp.com
next so inquire with the equipment manufacturer about
Mimaki www.mimakiusa.com
conditions and work with your Sabic-IP representative to
trial some Lexan with the equipment manufacturer. Durst www.durstus.com
Inca www.incadigital.com
Epson www.epson.com
AGFA www.agfa.com
Dupont Cromaprint www.dupont.com
Anhui Liyu www.ahliyu.com
Digirex www.digirexdigital.com
Flora www.floradigital.com
Gerber Scientific Products www.gspinc.com
Infiniti www.infinitidigitech.com
Luscher www.luescher.com
Neolt www.neolt.it
SkyJet www.skyair-ship.com
Teckwin www.teckwin.com

SABIC Innovative Plastics 27

13 pt praxis light

28 SABIC Innovative Plastics

Bonding or water, in the case of water-based adhesives. This
Many different adhesive systems, as well as heat sealing, curing process increases the cycle time and limits the
can be used with SABIC Innovative Plastics Specialty handling of components after bonding. The adhesive
Film and Sheet’s film. The choice of adhesives will be type primarily determines the characteristics of an as-
dictated by the specific application. sembly. (Table 34)

Amorphous materials like Lexan and Ultem are easier Table 35 lists a number of adhesive suppliers with adhe-
to bond because of their limited chemical resistance. sives that are compatible with Lexan film. The list is not
The solvents in the adhesives make the surface swell all-inclusive, and testing is recommended prior to use.
and dissolve, resulting in good adhesion. A drawback is Note that some adhesives may have an adverse effect
the sensitivity of amorphous materials to environmental on some inks used on Lexan film.
stress cracking. It takes time for evaporation of solvents

Table 34: Adhesive Types and Characteristics

Type-Function Adhesive Curing Characteristics

Structural (gap filling) Epoxies A+B comp. chem./moist./heat/creep resist.,
chemical reaction stiffness, brittle, low impact
Polyurethanes A+B comp. ductile, flexible, impact, creep, high peel strength
chemical reaction
Sealants (gap filling) Polyurethanes chemical reaction ductile, flexible, impact, creep, high peel strength
moisture
Silicones chemical reaction impact, flexible, heat resistance, low shear
moisture
Contact (not filling) Polyurethanes chemical reaction see above to Polyurethanes
Cyano acrylates chemical reaction fast curing, high peel strength,
humidity chem. aggressive, moisture sensitive
Hot melts EVA temperature fast adhesion, low temp. resistance
chemical reaction
Solvents (not filling) MeC12. M.E.K. physical easy application, high strength,
Toluene evaporation stress cracking, polluting, toxic

SABIC Innovative Plastics 29

Table 35: Manufacturers with Adhesives Compatible with SABIC Innovative Plastics Specialty Film and Sheetfilm

Manufacturer Product
Pressure Sensitive Transfer Adhesives
3M www.3m.com
Avery Dennison www.averydennison.com
Dielectric Polymers www.dipoly.com
Flexcon www.flexcon.com/index-flash.htm
Scapa www.scapaeurope.com
www.scapaasia.com
www.scapana.com
Mac Tac www.mactac.com
Henkel www.henkel.com
www.nationaladh.com/Adhesives/
Sun Process http://sunprocess.com
H.B. Fuller Company www.hbfuller.com/
One and Two-Part Epoxies/Urethanes
Henkel www.henkel.com
www.nationaladh.com/Adhesives/
Huntsman www.huntsman.com/
Rohm & Haas www.rohmhaas.com
H.B. Fuller Company www.hbfuller.com/
Hotmelt Adhesives
3M www.3m.com
Henkel www.henkel.com
www.nationaladh.com/Adhesives/
H.B. Fuller Company www.hbfuller.com/
Contact Cements
3M www.3m.com
Solvent Adhesives
Local chemical and warehouses distributors Dichloromethane methylene chloride) Caution: lowers impact
IMD Adhesion Promoters
SunChemical Aqualam www.sunchemical.com/products.aspx
Seiko Advance N3A, JT10, JT20 www.seikoadvance.co.jp/
Pröll KG Aquapress www.proell.de

Table 36: Overview of assembly techniques for SABIC Innovative Plastics Specialty Film and Sheet’s films

Material Welding Adhesives Mechanical Assembly

Lexan Vibration, Ultrasonic, Generally easy, critical are Cyanoacrylate Avoid high stresses at point
Induction possible and Acrylic because of stress cracking loadings
Ultem Vibration, Ultrasonic, Induction Epoxy, PUR(2K), Silicones possible, Acrylic, All techniques possible
possible Cyanoacrylate critical because of stress
cracking
Valox Vibration, Ultrasonic, Induction Epoxy, PUR, Silicones, All techniques possible
possible Cyanoacrylate possible Prevent creep

30 SABIC Innovative Plastics

Heat Sealing 3. S cratches and minor abrasions can be minimized by
Three methods are satisfactory for heat sealing Lexan using a mild automobile polish. We suggest that a
films: impulse, jaw, and ultrasonic sealing. Preliminary test be made on a small area of Lexan film with the
testing indicates that the ultrasonic technique is the polish selected and that the polish manufacturer’s
most reliable, producing peel strengths of 8.6 lbf instructions be followed, prior to using the polish on
per inch (38 N per 25 mm) of width. Speeds for this the entire sheet of film.
method range from 6 in/s (150 mm/s) with 0.003 inch 4. F inally, thoroughly rinse with clean water to remove
(0.075 mm) film to 1.2 in/s (30 mm/s) for 0.020 inch any cleaner residue and dry the surface with a soft
(0.500 mm) film. cloth to prevent water spotting.

Impulse and jaw methods produce bonds ranging from Cleaning Procedure for Large Areas - Automated
3-14 lbf per inch (13-62 N per 25mm) of width. As 1. C
 lean the surface using a high-pressure water cleaner
shown in Table 37, the impulse method is more rapid, (max. 100bar or 1,450psi) and/or a steam cleaner. We
particularly with the thinner gauges. It should be noted suggest that a test be made on a small area, prior to
that these times were obtained on laboratory equi- cleaning the entire sheet of film.
pment with only single jaw heating. Times on actual 2. U
 se of additives to the water and/or steam should be
production equipment running at normal operating avoided.
temperatures would be much faster.
Other Important Instructions for All Specialty
Table 37: Sealing Time (Seconds) Film and Sheet Films:
• Never use abrasive or highly alkaline cleaner on Speci-
Method Thickness (inch (mm)) alty Film and Sheet film materials.
• Never use aromatic or halogenated solvents like tolu-
0.001 0.003 0.005
ene, benzene, gasoline, acetone or carbon tetrachlo-
(0.025) (0.075) (0.125)
ride on Specialty Film and Sheet film materials.
Impulse 2.5 3.5 4.5 • Use of incompatible cleaning materials with Specialty
Jaw 7 8 9 Film and Sheet film materials can cause structural
and/or surface damage.
• Contact with harsh solvents such as methyl ethyl
Jaw sealing requires temperatures of 400°F (205°C) ketone (MEK) or hydrochloric acid can result in surface
for 0.001 inch (0.025 mm) film and 430°F (220°C) for degradation and possible crazing of Specialty Film
the two thicker films. Dielectric sealing is not practical and Sheet film materials.
with common commercial equipment because of Lexan • Never scrub with brushes, steel wool or other abrasive
films’ low dissipation factor. materials.
• Never use squeegees, razorblades or other sharp
Cleaning instruments to remove deposits or spots.
Periodic cleaning using correct procedures can help to • Do not clean Specialty Film and Sheet film materials
prolong service life. For cleaning, it is recommended in direct sunlight or at high temperatures as this can
that the following instructions be adhered to: lead to staining.
• For all mentioned chemicals consult the manufac-
Cleaning Procedure for Small Areas - Manual turer’s material safety datasheet (MSDS) for proper
1. Gently wash film with a solution of mild soap and safety precautions.
lukewarm water, using a soft, grit-free cloth or
sponge to loosen any dirt or grime.
2. Fresh paint/ink splashes, grease and smeared glazing
compounds can be removed easily before drying
by rubbing lightly with a soft cloth using petroleum
ether (BP65°), hexane or heptane. Afterwards, wash
the sheet using mild soap and lukewarm water.

SABIC Innovative Plastics 31

 20. (SI)
Static Control Die Cutting
Air ionization, liquid treatments and special cleaners SABIC Innovative Plastics Specialty Film and Sheetfilms 21. (metric)
are used for static control with SABIC Innovative Plastics can be die cut with either steel rule, matched me-
Specialty Film and Sheet’s films. tal and, to a lesser extent, rotary dies. Lexan’s shear
A partial listing of suppliers can be found below. strength of 10,000 psi (70 N/mm2), relatively low in
comparison to metals, simplifies and eases tool design
Static Control and Web Cleaners for Lexan Film and processing. In addition, parts may be cut from
single or multiple sheets depending on press tonnage,
Alpha Innovation, Inc www.stopstatic.com working area and material thickness.
ElectroStatics, Inc www.electrostatics.com
The press tonnage required to die cut Lexan film can be
NRD www.nrdstaticcontrol.com determined by the simple formula:
Polymag www.polymagtek.com
(P) (A) {P} {A}
Simco www.simco-static.com F= F=
9807 N/metric ton 2000 lb/ton
Teknek www.teknek.com
R.G. Egan www.rgegan.com F = press tonnage
P = shear strength of Lexan film
A = cross-sectional area

The cross-sectional or shear area can be found by

multiplying the total length of the cut by the film
thick-ness. For example: (Note: SI and metric examples
are not equal)

Figure 20 shows a 4” x 10” rectangle with a 2” diameter

circular cutout in the center.

Figure 21 shows a 100 x 300 mm rectangle with a 50

mm diameter circular cutout in the center.

300 mm

2” 50 mm
4” 100 mm

Total length of cut = 2L + 2W + πD Total length of cut = 2L + 2W + π D

= 2 (4”) + 2(10”) + π(2”) = (2) (300 mm)
= 8” + 20” + 6.28” + (2) (100 mm) + π (50 mm)
= 34.28” = 600 mm + 200 mm + 157 mm
Shear Area = total length x thickness of film = 957 mm
= 34.28” x 0.010” Shear area = (total length) x (thickness of film)
= 0.343 in2 = 957 mm x 0.250 mm
= 239.25 mm2
Press tonnage Press tonnage

F = (P) (A) = (10,000 lb/in ) (0.343 in”) F = (P)(A) = 70 N/mm x 239.25 mm = 1.7 metric ton
2 2 2

2000 2000 lb/ton 9807 9807 N/metric ton

F = 1.72 ton

20 21

32 SABIC Innovative Plastics

 22. Steel Rule Die
Of the three die cutting methods described earlier, steel SABIC Innovative Plastics Specialty Film and Sheet films
rule die cutting is the most popular and least expensive can be successfully “kiss cut” with platen presses having 23. Bevel Designs
method used. Generally, a 2-point rule (0.0275 inch or close tolerance impression adjustment controls. In kiss
0.7 mm thick) is used to cut SABIC Innovative Plastics cutting, a side bevel is recommended in the die design.
Specialty Film and Sheet films up to 0.015 inch or 0.375 The problem of cutting through both the printed SABIC
mm thick, whereas a 3-point rule (0.04 inch or 1.0 mm Innovative Plastics Specialty Film and Sheet films and
thick) is used for films greater than 0.015 inch or 0.375 transfer tape or liner can be solved by using a heavier or
mm in thickness. When careful make-ready is applied, thicker liner.
over 25,000 cuts can be obtained from a steel rule die. For instance, using a 0.006 in. (0.15 mm) liner (3M,
9668) versus a 0.004 in. (0.10 mm) liner (3M 468) will
Steel rule dies are manufactured by two different me- provide a flatter piece and cushion the impact of the
thods: laser and jig. The laser cut die will maintain the steel rule. Obviously the thicker liner will be more dif-
most accurate dimensional tolerances (to ± 0.004 in or ficult to cut through completely, and so the kiss-cutting
0.1 mm), while the jig cut die will provide the least (± problem will be reduced.
0.016 in or 0.4 mm). In manufacturing a die, a steel rule
is fitted into a pre-cut pattern in a wooden die board. Finally, two other methods are used to die cut SA-
Stripping rubber on each side of the rule eases part BIC Innovative Plastics Specialty Film and Sheet films;
ejection. Generally, stripping rubber should be no more matched metal and rotary. Matched metal dies consist
than 0.12 in (3 mm) above the height of the rule. Figure of hardened male and female die halves. Match metal
22 illustrates a typical steel rule die. die cutting operates by shearing the film and is used
to cut intricate patterns, to maintain tight dimensional
Several different steel rule bevel designs are available, as tolerances (± 0.001 in. or 0.025 mm), and to cut thicker
illustrated in Figure 23. films on larger volume production runs (100,000+).
Clearance between dies should be less than 0.001 inch
Although the centre bevel rule is the most common or 0.025 mm.
and provides the longest life in terms of wear, cleaner
cuts can be attained by using a facet bevel rule. In roll-to-roll film processing (i.e. flexographic printing),
The longer bevel reduces material displacement, espe- rotary dies can be used for cutting
cially with thick material, while the broad tip remains SABIC Innovative Plastics Specialty Film and Sheet films.
sharp. The flush bevel rule also provides clean cuts, but This process offers a high-speed production capability
has a weak tip that is susceptible to roll-over. To maxi- versus steel rule and matched metal die cutting.
mise both cut quality and rule longevity, the side bevel
rule is recommended. Table 38 is a partial list of diemakers for SABIC Innova-
In this case the long bevel side should face the scrap or tive Plastics Specialty Film and Sheet films.
trim of the piece.
Table 38: Diemakers for SABIC Innovative Plastics
Depending on rule design, size and shape of part and Specialty Film and Sheet Films
thickness of film, the cut parts will be slightly different
in size than the rule: holes will be smaller and cut outs Marbach Werkzeugbau GmbH www.marbach.com
will be larger. Therefore, dies are usually manufactured
A&H Formes Ltd. www.ah-formes.co.uk
on either end of the tolerance range. For example, dies
to cut holes are made slightly larger than the part size Millennium Die Group www.millenniumdie.com
indicated on the print. Atlas Die, LLC www.atlasdie.com
Independent Die Service www.wsids.com

Wood
Steel Rule
Foam Rubber
Film
Centre Facet Flush Side
Platen

22 23

SABIC Innovative Plastics 33

 24. xxx
Embossing Die Design
SABIC Innovative Plastics Specialty Film and Sheet films Dies for embossing can be matched male/female 25. xxx
can be embossed to form raised areas for membrane or either male or female with a rubber counter die. 26. Radii
switch keys, or raised letters and design. Thicknesses up Materials include metals such as zinc, magnesium, brass,
to 0.01 in. (0.250 mm) can be readily embossed, and aluminium and steel, as well as polyester/fibreglass and
films up to 0.02 in (0.500 mm) can be embossed in silicone rubber. Sharp detail usually requires the use of
certain configurations. metal dies.
Dies should be designed so the clearance between the
For films over 0.02 in (0.500 mm) thick, thermoforming male and female sides is approximately equal to the
should be used to create three-dimensional effects. film thickness. Minimum draft angles of 3° should be
Embossing raised areas for membrane switch keys may designed into both male and female walls, as shown in
significantly decrease switch life. Since switch size and Figure 25.
travel, film thickness, embossed height and working
environment can all be factors, product life cycle testing To keep localised stresses in the embossed overlay to
is strongly recommended. a minimum, embossing dies should contain no sharp
corners at points in contact with Lexan film. Radii at all
A wide variety of embossed configurations is possible internal corners will reduce stress concentration and
with SABIC Innovative Plastics Specialty Film and Sheet- help prevent failure from fatigue or impact. As a rule
films, as shown in Figure 24. of thumb, radii should be equal to, or greater than, the
thickness of the film. In other words, a 0.01 in. (0.250
mm) thick Lexan film should contain a 0.01 in. (0.250
mm) minimum radius at any corner (Figure 26).

Heated platens with temperatures as high as 290 F (143

C) may also be used to reduce stresses from embossing
and to obtain more emboss detail.

Embossing Press
Several types of press can be used to emboss SABIC
Innovative Plastics Specialty Film and Sheet films. The
most popular of these is the platen press, which also
can be used in steel rule die cutting.

Ridge (window frame)

Raised Platform

Raised Dome

Debossed Platform

24

r=T
C = Clearance
T = Film Thickness
C=T r = Radius
3° T = Film Thickness

25 26

34 SABIC Innovative Plastics

 27. xxx
Part Design Thermoforming
The following design recommendations for embossed Lexan film’s high melt strength makes it ideal for 28. xxx
parts will help to minimise stress and maximise key life thermoforming. Recommended forming techniques are 29. xxx
in membrane switch applications. pressure forming and vacuum forming, with or without
plug-assist over female molds, along with drape-forming
a. Embossed Width over male molds. The following guide-lines should be
The width of ridge-type embossing should be equal followed for successful forming.
to, or greater than, five times the film thickness.
If adhesive and liner are not zoned away from the
embossed area, their thickness must be added to the
film thickness when determining width (Figure 27).
B
b. Embossed Height T
The height of an embossed area should be no grea-
ter than 2.5 times the material thickness (excluding
adhesive and liner), with material thickness included B≥5xT
in the measurement (Figure 28). Greater embossed
heights can be attained, but are not recommended 27
for membrane switch keys.

c. Embossed Spacing
Spacing between embossed areas should not be less
than 0.06 in. (1.5 mm) to minimise distortion of the T
sheet after embossing (Figure 29) B
B ≤ 2.5 x T
d. Inks/Adhesives
Inks used on SABIC Innovative Plastics Specialty Film
and Sheetfilm that is to be embossed should be com- 28
patible with the material and also somewhat flexible.
The ink coating will be stretched and bent, and may
fracture slightly. This is an important consideration in
back-lit applications, and may require special hand-
ling by the printer. B ≥ 1.5mm

Adhesives should be zoned away from the embos- B

sed area wherever possible to facilitate embossing. If
adhesive is required in the embossed area, it should be
carried on a polyethylene liner instead of on paper.
29

SABIC Innovative Plastics 35

 30. Vacuum Forming
Mold Design Because of the high tensile strength of Sabic Innovative (Male Mold)
Male molds as shown in Figure 30 are preferred for Plastics Specialty Film and Sheet film undercuts will be
31. Vacuum Forming
deep draws and interior detail appearance parts. Good troublesome when forming film 0.02 in. (0.500 mm) (Female Mold)
material uniformity can be maintained in depth of draw and 0.03 in. (0.750 mm) thick. If they cannot be avoi-
ratios between 1:1 and 2:1. A draft of 3-5 degrees per ded, split molds with sliding sections solve the problem 32. Mold with Cam and
Removable Inserts
side and a micro roughening surface finish gives easy of removing the part after forming. Figure 32 shows
parting from the male mold and will avoid air entrap- an example of a tool with a cam as well as a removable 33. Release for Mold with
Cam and Removable
ment. insert that allows for an undercut. Inserts

Female molds like the example shown in Figure 31 are Recommended tooling materials are steel and cast
recommended when exterior detail is important. Unless aluminium for attractive, durable surface finishes,
plug-assisted or mechanically formed, parts made on maintenance of close tolerances, and rapid heating and
female molds will generally be limited to a maximum cooling. Materials such as silicone, hardwood, fibre-
depth: draw ratio of 1:4 with a draft of between 2-3 glass, melamine and phenolic are only for prototype or
degrees per side. limited-production work.

A B C

Plastic Sheet Thick Areas

Clamp Thin Areas

Formed Part

Removable Insert
Mold Vacuum
30 Mechanically
Retracted
Arm
A B C
Air-actuated
Formed Part
Solenoid
Plastic Sheet
Thick Areas

Seal Mold Vacuum

Clamp chamber

Thin Corners
Vacuum

31

Removable Insert

Mechanically Formed Part

Retracted
Arm

Air-actuated
Solenoid

Vacuum Vacuum
chamber chamber

32 33

36 SABIC Innovative Plastics

 34. Forming Tool with
Vacuum holes of 0.02 in. (0.50 mm) diameter and/or Drying Undercuts
shims that supply adequate vacuum flow are recom- Despite the low moisture absorption (0.35%), which
35. Optimum Appearance Sag
mended for male and female molds. Where fine detail contributes to the excellent dimensional stability of
is required, vacuum holes should be spaced as close as SABIC Innovative Plastics Specialty Film and Sheetfilm
0.25 in. (6.4 mm). On large flat surfaces, 1 to 3 inches parts, drying of film stock is essential. A circulating
(25 to 75 mm) spacing is adequate. Back drilling with oven set at 257°F (125°C) is recommended for drying
larger drills (i.e. > 0.25 in. or 6 mm) is suggested to sheeted film stock. Residence times are indicated in
speed up evacuation. Table 39.

Mold Temperature Table 39: Drying Time for Sheeted Lexan Film
Optimal forming of SABIC Innovative Plastics Speci- at 257°F ( 125°C)
alty Film and Sheetfilms requires heated molds. Mold
heating can facilitate making deep-drawn parts with Gauge in. (mm) Time (min.)
plug-assist, producing superior surface quality and mini-
0.01 (0.250) 15
mised formed-in stresses. Mold temperature affects the
appearance of the formed part, length of the forming 0.015 – 0.02 (0.375-0.500) 20
cycle and size of the finished part. Minimum mold 0.02 – 0.03 (0.500-0.750) 30
temperatures of 194°F (90°C) are recommended, 248-
257°F (120-125°C) when appearance is critical. Oil and
electrical systems are recommended for mold heating Web-fed forming of SABIC Innovative Plastics Specialty
when forming SABIC Innovative Plastics Specialty Film Film and Sheetfilm rollstock up to 0.03 in. (0.750 mm)
and Sheet film. may be accomplished without pre-drying. Care must be
taken to allow the film to reach forming temperature
gradually to avoid bubbling in the web. Sandwich style
heating units are recommended to be four times the
Air length of the forming station dimension (i.e. 12 in. tool
Air
Vacuum Hole = 48in tunnel or a 300 mm tool = 1200 mm tunnel).
Vacuum Hole
Forming Temperatures
Normal processing temperatures for SABIC Innovative
Vacuum Box Plastics Specialty Film and Sheetfilm range between
374 - 410°F (190-210°C). For optimal gauge versus tem-
Vacuum Line to Surge Tank perature parameters see Table 40.

34 Table 40: Gauge Versus Forming Temperature

Gauge in. (mm) Temperature °F (°C)

0.01 (0.250) 374 - 383 (190 - 195)
0.02 (0.500) 383 - 392 (195 - 200)
0.03 (0.750) 392 - 410 (200 - 210)

Sandwich heaters (top and bottom) are preferable so

that both sides of the film can be heated simultane-
ously. See Figure 34 for optimum sag appearance. This
recommendation avoids overheating one side and
underheating the other which might create strains and
stresses, excessive sag and degradation of material on
the heater side.

25-50 mm

35

SABIC Innovative Plastics 37

 Contact
13 us light
pt praxis

Americas:
SABIC Innovative Plastics
Specialty Film & Sheet
One Plastics Avenue
Pittsfield, MA 01201
USA
T +1 413 448 7110
F +1 413 448 5573

Europe:
SABIC Innovative Plastics
Specialty Film & Sheet
Plasticslaan 1
4612 PX Bergen op Zoom
The Netherlands
T +31 164 292911
F +31 164 292940

Pacific:
SABIC Innovative Plastics
Specialty Film & Sheet
1266 Nanjing Road (W)
16th Floor, Plaza 66
200040 Shanghai
China
T +86 21 6288 1088
F +86 21 6288 0818

email: sfs.info@sabic-ip.com

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SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS PRODUCTS OR SERVICES DESCRIBED HEREIN. Each user is responsible for making its own determination as to
the suitability of Seller’s products, services or recommendations for the user’s particular use through appropriate end-use testing and analysis. Nothing in any document or oral statement
shall be deemed to alter or waive any provision of Seller’s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a writing signed by Seller. No statement by Seller
concerning a possible use of any product, service or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of Seller or as a
recommendation for the use of such product, service or design in a manner that infringes any patent or other intellectual property right.

SABIC Innovative Plastics is a trademark of SABIC Holding Europe B.V.

* Trademark of SABIC Innovative Plastics IP B.V.

©2009 SABIC Holding Europe B.V.

All Rights Reserved

www.sabic-ip.com/sfs Printed in The Netherlands