Product Information Guide CALIBRE. Polycarbonate Resins. Impact Strength. Heat Resistance. Optical Clarity

Transcription

1 Product Information Guide Impact Strength Heat Resistance Optical Clarity CALIBRE Polycarbonate Resins

2 CALIBRE Polycarbonate Resins Meeting the Needs of a Growing Market The Right Resins for a Multitude of Needs Product Identification Codes. 4 Melt Flow Rates Color Codes Balancing Performance and Processing Molecular Structure Rheology Impact Properties Thermal Properties Optical Properties Electrical Properties Additional Performance Properties Chemical Resistance Agency Compliance Processing Guidelines Injection Molding Importance of Drying Machine Selection Molding Conditions General Rules for Effective Troubleshooting Extrusion Other Fabrication Technologies Purging Finishing Appendix: Typical Properties Data Series Food Contact Resins , 3 EP and 3V Series General Purpose Resins.. 4 IM 4 Series Impact Modified Resins Series Branched Resins Series Ignition-Resistant Resins Series Superior Ignition-Resistant Resins.. 43 Series Optical Media Resins Series Glass-Reinforced Resins Series Glass-Reinforced, Ignition-Resistant Resins Series Health Care Resins Handling Considerations Hazards and Handling Precautions Combustibility Disposal Environment Product Stewardship Customer Notice

3 CALIBRE Polycarbonate Resins Meeting the Needs of a Growing Market Since Dow Plastics introduced CALIBRE* polycarbonate resins in 984, we ve worked continuously with customers to develop and refine a product line that meets the increasing demand for polycarbonate. Dow s proprietary production process gives CALIBRE resins very high ductility and toughness over a wide temperature range. That means you can take advantage of a broad continuum of CALIBRE resins developed for a variety of needs from electronics to compact discs to ophthalmic applications. In addition to a continually evolving product family, increased global production capabilities and capacity help Midland, Michigan (Dow World Headquarters) Clinton, Tennessee Freeport, Texas Stade, Germany Terneuzen, the Netherlands Yuso,South Korea Niihama, Japan Manufacturing and Research Facilities for CALIBRE Polycarbonate Resin Dow Plastics, a business group of The Dow Chemical Company and its subsidiaries. *Trademark of The Dow Chemical Company. 2

4 CALIBRE Polycarbonate Resins ensure delivery of consistent, high-quality CALIBRE resins virtually anywhere in the world. And, Dow s global Statistical Quality Control and Statistical Process Control programs allow continuously improved processes and quality. Our production facilities and laboratories are QS-9 and A2LA certified. Most importantly, our customers can take advantage of our technical expertise and service including customer service, account development representatives (ADRs), technical service and development (TS&D), research and development (R&D), application development engineers (ADEs) and design support personnel. This dedicated staff can help you turn today s tough design parameters into tomorrow s product successes. In the following pages, you ll find technical product information that explains the benefits and properties of CALIBRE resins so you can select the best resin for your application. There s also processing information for injection molding, extrusion and a variety of other fabrication methods. To find out more about how you can take advantage of CALIBRE resins and the resources Dow has to offer, call DOW(4369). In Mexico, call Through the use of CALIBRE polycarbonate resins, Critical Disposables, Inc., has developed a breakthrough in the design of its heart catheterization manifold. CALIBRE resins provide the required strength, clarity, dimensional stability, and resistance to gamma sterilization needed for the one-piece design and snap-on rotator. 3

5 CALIBRE Polycarbonate Resins The Right Resins for a Multitude of Needs The Biojector 2 Needle-Free Injection Management System, manufactured by Bioject Inc., utilizes jet-injection technology to help eliminate the risk of contaminated needlestick injuries and other complications associated with needles. The Biojector 2 features a patented disposable syringe and plunger made with CALIBRE polycarbonate resin. CALIBRE resin provides the clarity, strength and rigidity essential for reliable performance under high pressure. Dow Plastics currently offers more than 75 unique CALIBRE resins. These products are grouped into different series based on key performance attributes such as FDA compliance, ignition resistance and glass-reinforcement. Product Identification Codes Each CALIBRE resin is identified by a three- or four-digit code (i.e., 2, 7, 5, etc.). This product identification system has been devised to help customers specify, order and use the CALIBRE resin best suited to their specific application. The first digit, or series number, identifies the broad product family. Following is a brief description of each series designation: 2 Series Food Contact Resins CALIBRE 2 Series resins comply with appropriate U.S. Food and Drug Administration (FDA) regulations for food contact applications (see page 27). These resins provide excellent impact resistance, heat distortion resistance and optical clarity. 3 and 3 EP Series General Purpose Resins Like the 2 Series, these CALIBRE resins offer exceptional impact resistance, heat distortion resistance and clarity. These properties make 3 and 3 EP Series resins useful for applications in the transportation, appliance, houseware, business equipment, recreation and service industries. CALIBRE 3 Series resins are offered in melt flow rates of 4, 6, and 5. CALIBRE 3 EP Series resins provide enhanced processability with a melt flow rate of 22. IM 4 Series Impact Modified Resins CALIBRE IM 4 Series impact modified resins are available in opaque formulations that offer benefits ranging from superior NOTE: The data provided in this brochure were acquired, unless otherwise noted, by the standardized test methods of the American Society for Testing and Materials (ASTM). For full details of any test, the applicable ASTM standard should be consulted. Also, unless otherwise indicated, the property values for CALIBRE resins contained in this brochure are typical of the 3 Series, general purpose resins. 4

6 CALIBRE Polycarbonate Resins low temperature impact strength to easy processing with improved impact strength in highly filled formulations. 6 Series Branched Resins CALIBRE 6 Series branched resins offer increased melt strength versus CALIBRE 3 Series resins, while retaining similar impact strength, heat distortion resistance and clarity. Their increased melt strength makes these resins suitable for the profile extrusion and blow molding processes. 7 Series Ignition-Resistant Resins These CALIBRE resins provide both clarity (an average of 86 percent light transmission) and enhanced ignition resistance (UL94 rating of V- () in wall thicknesses down to.25 inch [3.2 mm]) while maintaining excellent physical properties and processability. This combination makes 7 Series resins well suited for use in electronic, optical, transportation and appliance applications. 89 Series Superior Ignition Resistant Resins 89 Series resins provide superior ignition resistance in opaque applications. Their UL94 ratings are V- () in wall thicknesses down to.625 inch (.6 mm), and 5VA () in wall thicknesses down to.25 inch (3.2 mm). Physical properties and processing are outstanding for this class of polycarbonate. These resins are typically used in electronic, business equipment, appliance and transportation applications. Series Optical Media Resins These high flow, high purity resins are formulated for use in optical media. For more information, contact your Dow sales representative or call DOW (4369). In Mexico, call Series Health Care (2) Resins CALIBRE 2 Series resins are formulated to meet the sterilization needs of the health care industry, while providing exceptional clarity, heat resistance, impact strength and processability. An ultra-clean, lens grade resin, CALIBRE LG 223, is available for applications where particulate contaminant counts are very stringent. This resin is produced for ophthalmic applications where optical clarity is of the utmost importance. CALIBRE 26, 26 and 27 resins are used in applications involving steam or ethylene oxide sterilization though suitability for use in these applications is dependent upon autoclave cycle times and temperatures. Typical applications include hemodialyzers, surgical instruments, cardiotomy reservoirs, blood centrifuge bowls, I.V. connectors and safety syringes. CALIBRE 27 resins were developed to provide a product with enhanced mold release characteristics. Finally, CALIBRE MegaRad* 28 Series resins provide endusers of radiation sterilized medical devices a color closer to the waterclear look of the natural resin. When exposed to high energy radiation (gamma or electron beam), CALIBRE MegaRad 28 Series resins exhibit a 5 percent reduction in color shift compared to general purpose polycarbonate. () CALIBRE polycarbonate resins containing ignitionresistant additives do not readily support ignition. However, they will burn under the right conditions of heat and oxygen supply. The resins should not be exposed to direct flame or extreme heat. Results of small-scale flammability tests on these or any other materials are not to be considered indicative of the behavior of these materials under actual fire conditions. (2) NOTICE REGARDING LONG-TERM MEDICAL IMPLANT APPLICATIONS: The Dow Chemical Company does not recommend any medical grade resin or film product for long-term medical implant applications in humans, i.e., for more than 72 hours (or 3 days, for PELLETHANE* polyurethane elastomers). Further, Dow does not recommend the use of any resin (or film) product for use in cardiac prosthetic devices regardless of the time period that the device will be wholly or partially implanted in the body. Such applications include, but are not limited to, pacemaker leads and devices, cardiac prosthetic devices such as artificial hearts, heart valves, intra-aortic balloons and control systems, and ventricular bypass assist devices. Dow does not recommend any nonmedical grade resin (or film) product for use in any human implant applications. * Trademark of The Dow Chemical Company. 5

7 CALIBRE Polycarbonate Resins 5 Series Glass-Reinforced Resins These glass-reinforced CALIBRE resins provide increased modulus and improved heat distortion resistance with minimal shrinkage. They also offer outstanding UL94 flammability ratings, and are used for applications in transportation, electronics and service parts. 7 Series Glass-Reinforced, Ignition-Resistant Resins The increased modulus, improved heat distortion resistance and dimensional stability of the 5 Series glass-filled resins is further enhanced with the CALIBRE 7 Series. This family of ignitionresistant, glass-reinforced products maintain a UL94 V- () flammability rating at wall thicknesses of.625 inch (.6 mm) and a 5VA () rating at wall thicknesses of.25 inch (3.2 mm). A structural foam (SF) formulation is also available () CALIBRE polycarbonate resins containing ignitionresistant additives do not readily support ignition. However, they will burn under the right conditions of heat and oxygen supply. The resins should not be exposed to direct flame or extreme heat. Results of small-scale flammability tests on these or any other materials are not to be considered indicative of the behavior of these materials under actual fire conditions. (2) NOTICE REGARDING LONG-TERM MEDICAL IMPLANT APPLICATIONS: The Dow Chemical Company does not recommend any medical grade resin or film product for long-term medical implant applications in humans, i.e., for more than 72 hours (or 3 days, for PELLETHANE* polyurethane elastomers). Further, Dow does not recommend the use of any resin (or film) product for use in cardiac prosthetic devices regardless of the time period that the device will be wholly or partially implanted in the body. Such applications include, but are not limited to, pacemaker leads and devices, cardiac prosthetic devices such as artificial hearts, heart valves, intra-aortic balloons and control systems, and ventricular bypass assist devices. Dow does not recommend any nonmedical grade resin (or film) product for use in any human implant applications. * Trademark of The Dow Chemical Company. for applications that require a combination of high modulus with low part weight and density. In the glass-filled, 5 and 7 series products, the two middle digits of the CALIBRE product identification code are used to indicate the percentage of glass content. For example, CALIBRE 7 resin contains percent glass, while CALIBRE 52 resin contains 2 percent. In all CALIBRE products, the last digit of the code indicates which additives if any are incorporated in the resin, as follows: = No additives = Mold release agent 2 = Ultraviolet light (UV) stabilizer 3 = Mold release and UV stabilizer For example, CALIBRE 33 is a general purpose resin (3 Series) with both mold release and UV stabilizer (3) added. (3) The addition of a UV stabilizer to a resin does not completely eliminate the effects of UV exposure. These effects may include color shift (yellowing, darkening or bleaching), decreased ductility, decreased impact resistance, decreased mechanical properties, decreased surface gloss, and/or increased haze. The purpose of a UV stabilization package is to slow down the rate at which these effects occur. Actual results may vary depending on application and other factors such as resin color, transparency and additives. Therefore, actual end-use testing is recommended. Melt Flow Rates In addition to the product indentification code, each CALIBRE resin (except the glass-reinforced and structural foam products), is identified by its specific melt flow rate aim point. Melt flow rates, which are determined using ASTM D 238, (3 C/.2 kg) test procedures, are indicated by listing the aim point, followed by MFR. The standard aim points available are 6, and 5 MFR with additional aim points offered in selected series. Color Codes Color code numbers are also used in specifying CALIBRE resins. Codes for standard tints and colors are listed in current price schedules. Code numbers for customized colors are assigned at the time of formulation. Table provides a listing of typical markets and applications that are well-suited to each series of CALIBRE resins. To help determine which CALIBRE resin is right for your application, read on and learn more about product properties. Or, contact the Dow Customer Information Center at DOW (4369). In Mexico, call

8 CALIBRE Polycarbonate Resins Table Typical Applications of Polycarbonate Resins Suggested CALIBRE Series Market Typical Applications Resin Automotive Instrument Panel Substrates 3 Series Light Lenses and Housings IM 4 Series Wheel Covers 5 Series Exterior Body Parts Interior Trim Cowl Vent Grille Sheet Glazing 3 and 3 EP Series Signs 6 Series Transportation Security Health Care (2) Hemodialyzers 2 Series Surgical Instruments Cardiotomy Reservoirs Blood Centrifuge Bowls I.V. Connectors Safety Syringes Opthalmic Media Optical Media Compact Discs (CDs) Series Digital Video Discs (DVDs) Electrical Lighting 3 Series Switches Appliance Refrigerators/Air Conditioners 2 Series Housing Components 3 and 3 EP Series Interior Parts IM 4 Series Crisper Trays 7 Series Vacuum Cleaners 8 Series Power Tools 5 Series Telecommunication Portable/Cellular Phones 7 Series Pagers 89 Series 5 Series 7 Series Information Computer Housings, Keyboards 7 Series Technology Structural Components 89 Series Equipment (ITE) Business Equipment 5 Series Data Enclosures 7 Series Housewares Beverage Containers/Serviceware 2 Series Restaurant Supplies 3 and 3 EP Series Packaging Water Bottles 2 Series Outdoor Power Gardening Tools 3 and 3 EP Series Equipment (OPE) (2) NOTICE REGARDING LONG-TERM MEDICAL IMPLANT APPLICATIONS: The Dow Chemical Company does not recommend any medical grade resin or film product for long-term medical implant applications in humans, i.e., for more than 72 hours (or 3 days, for PELLETHANE polyurethane elastomers). Further, Dow does not recommend the use of any resin (or film) product for use in cardiac prosthetic devices regardless of the time period that the device will be wholly or partially implanted in the body. Such applications include, but are not limited to, pacemaker leads and devices, cardiac prosthetic devices such as artificial hearts, heart valves, intra-aortic balloons and control systems, and ventricular bypass assist devices. Dow does not recommend any nonmedical grade resin (or film) product for use in any human implant applications. 7

9 CALIBRE Polycarbonate Resins Properties and Performance Balancing Performance and Processing A series of monolithic demonstration transparencies was designed for potential use as aircraft windshields and canopies using CALIBRE polycarbonate resin. The prototype transparencies are the result of an innovative molding technology for large parts that could greatly reduce the time and costs associated with the manufacturing and replacement methods presently being used. Their unique balance of impact strength, heat resistance and optical clarity is the key factor that makes CALIBRE polycarbonate resins the right choice for a multitude of applications. The ability to provide these three properties begins with the products molecular structure. Molecular Structure Precise control of chemical processing and state-of-the-art compounding technology allows us to provide many different CALIBRE resins. Figure shows the typical repeating molecular structure for CALIBRE polycarbonate resin. The bisphenol A component (moiety A) of the molecule is the principal contributor to the resin s relatively high glass transition temperature of 32 F (5 C). And, the high rotational mobility of the carbonyl group within the carbonate (moiety B) contributes to the high ductility and toughness of CALIBRE polycarbonate resins over a wide temperature range. To translate the chemistry of CALIBRE polycarbonate resins into part performance, several key properties must be considered. The molecular weight of the resin has an inverse relationship to the melt flow rate (MFR) or, in other words, the higher the molecular weight, the lower the MFR. This relationship is illustrated in Figure 2, along with other properties affected. The physical and mechanical properties of CALIBRE resins increase Figure Typical Polycarbonate Molecule CH 3 O C O C O CH 3 n Polyfunctional Hydroxy Component Carbonyl Component 8

10 CALIBRE Polycarbonate Resins Properties and Performance with decreasing MFR. However, processing becomes more difficult as MFR decreases. Thus, a compromise is necessary and engineers, designers and fabricators must choose between optimum physical and mechanical properties and high flow characteristics that permit the filling of complex molds. The following section provides information on specific mechanical properties and how they are affected by MFR, temperature and additives. While this information should be considered during design, it is important to remember that ultimate part performance depends on many factors, including application and intended use environment, part design and mold design. Specific parts should be designed with their own special performance and end-use requirements in mind. It is strongly recommended that even after material properties and design considerations have been applied to the development of a part, prototypes be produced first and thoroughly tested under expected end-use conditions before committing the design to full-scale production. For design assistance, contact Dow s Technical Service and Development specialists. Figure 2 Molecular Weight-Melt Flow Relationship of Polycarbonate Resins High Molecular Weight Low Molecular Weight Low Melt Flow High Melt Flow Stiffer Processing Ease of Processing Maximum Physical- Mechanical Properties Reduced Physical- Mechanical Properties 9

11 CALIBRE Polycarbonate Resins Properties and Performance Rheology Polycarbonate resins have higher melt viscosities than many other thermoplastics. Figure 3 shows typical viscosity versus shear rate curves for CALIBRE 3 and 3 EP Series resins of various melt flow rates. At shear below about sec- (during extrusion), the melt viscosities of these polymers are essentially Newtonian, so changes in shear rate have little or no effect on melt viscosity. However, above sec- (during injection molding), melt viscosity actually decreases as shear rates increase making the resins even more processable. Figure 4 shows a sharp decrease in melt viscosity upon heating, which indicates that CALIBRE resins are easier to process at higher temperatures. The high thermal stability of CALIBRE resins allows processing at these higher temperatures. Figure 3 Viscosity versus Shear Weight at 575 F (32 C), CALIBRE 3 and 3 EP Series Resins Corrected Viscosity, poise MFR 6 MFR MFR 5 MFR 22 MFR 2 3 True Shear Rate, /sec 4 Figure 4 Viscosity versus Temperature, CALIBRE 3 and 3 EP Series Resins Corrected Viscosity, poise MFR 5 (26) 5 MFR MFR 55 (288) Temperature, F ( C) 3 MFR 6 (36)

12 CALIBRE Polycarbonate Resins Properties and Performance Impact Properties CALIBRE polycarbonate resins meet a wide range of impact requirements from.5 to 8. ft-lb/in (8 to 95 J/m) notched Izod impact strength. However, understanding the balance of end-use temperature and impact requirements is crucial in selecting a resin for a specific application. Impact Strength The impact strength of CALIBRE resins is measured by notched Izod, tensile impact and instrumented dart impact testing. CALIBRE polycarbonate resins offer excellent impact resistance 8 ft-lb/in (95 J/m) with low MFR resins, and good impact of 4 ft-lb/in (75 J/m) with high MFR resins (ASTM D 256). However, low temperatures, sharp notches or thick sections may cause a decrease in impact strength. Also, high levels of additives, such as colorants, release agents, glass reinforcement, UV stabilizer and ignition-resistant packages also affect impact strength, especially in higher MFR resins. Whether you re selecting a polycarbonate material for an existing application, or designing a new polycarbonate application, mechanical performance must be considered along with fabrication requirements. For more detailed information, see pages As previously stated, all available data indicate that maximum mechanical performance and maximum ease of processing are inversely proportioned for polycarbonate resins. That is, for applications requiring optimum impact properties, a low melt flow rate material would generally be the best choice. For applications where impact isn t as crucial, but optimum processing is a must, a higher melt flow rate material would be the best selection. However, CALIBRE polycarbonate resins have been designed to offer the best of both worlds outstanding mechanical properties at higher melt flow rates.

13 CALIBRE Polycarbonate Resins Properties and Performance Table 2 Notched Izod for Various Part Thicknesses, CALIBRE 3 and 3 EP Series Resins () Part Notched Izod, -mil notch Thickness 3 MFR 6 MFR MFR 5 MFR 22 MFR in mm ft-lb/in J/m ft-lb/in J/m ft-lb/in J/m ft-lb/in J/m ft-lb/in J/m () Typical property values; not to be construed as specifications. Figure 6 Izod Impact Strength at Various Temperatures, CALIBRE 3 and 3 EP Series Resins 2 F (38 C) 68 Notched Izod, ft-lb/in F (23 C) F (-29 C) J/m Melt Flow Rate, g/ min Figure 7 Notched Izod versus Temperature, CALIBRE 3 and 3 EP Series Resins 2 68 Notched Izod, ft-lb/in 5 3 MFR 6 MFR MFR 5 5 MFR MFR J/m -4 (-4) -2 (-29) (-8) 2 (-7) 4 (4) 6 (6) 8 (27) (38) 2 (49) Temperature, F ( C) 2

14 CALIBRE Polycarbonate Resins Properties and Performance Figures 6 and 7 show the effect of temperature and melt flow rate on impact values. As the temperature increases, the mobility of the polymer molecules increase resulting in improved ductility and impact strength of the resin. Figure 7 clearly demonstrates the importance of selecting the proper melt flow rate resin when low temperature environments are a concern. As melt flow rate increases, the temperature at which the notched Izod impact strength drops significantly, reflecting a brittle break increase. The lower melt flow rate resins remain ductile with high impact energies at lower temperatures. Figure 8 illustrates melt flow rate versus notched Izod for three different notch radii. With a -mil notch, polycarbonate resin retains its high impact strength of 6 to 9 ft-lb/inch (98 to 5 J/m) for the MFR shown. When the stress is concentrated on a 5-mil notch, the impact strength is retained to about 2 MFR, at which point it decreases significantly. These notched impact resistance studies indicate that low MFR resins are relatively insensitive to notch sharpness at least down to a 5-mil notch. However, above about MFR, notch sensitivity may become a more important factor requiring design consideration. Part thickness also effects impact strength, as shown in Table 2. Lower MFR resins retain their high impact strength in samples up to.88 inch (4.8 mm) thick. The higher MFR resins lose impact in samples that are between.25 and.88 inches (3.2 and 4.8 mm) thick. Figure 8 Notched Izod versus Melt Flow Rate, CALIBRE 3 and 3EP Series Resins 2 mil notch 68 Notched Izod, ft-lb/in mil notch mil notch J/m 5 5 Melt Flow Rate, g/ min

15 CALIBRE Polycarbonate Resins Properties and Performance Instrumented Dart Impact The instrumented, high-speed, dart impact test yields a plot of the force (load) and elongation (displacement) required to puncture a disc with a dart. The dart delivers a multiaxial impact, which is measured to determine the total energy needed to fracture the disc. Figure 9 is a plot of the total energy required to fracture injection molded,.25 inch (3.2 mm) thick discs versus the melt flow rates of CALIBRE 3 and 3 EP Series resins at -2, 73 and F (-29, 23 and 38 C). The test was conducted according to ASTM D 3763, using a.5 inch (2.7 mm) diameter dart and a.5 inch (38. mm) diameter aperture. As was evident in previous tests, the impact strength of the resins decreases slightly with increasing melt flow rate. The lower melt flow rate resins are seen to be slightly tougher than their higher melt flow rate counterparts. However, all samples exhibited ductile behavior. Figure 9 Instrumented Dart Impact Strength versus Melt Flow Rate, CALIBRE 3 and 3 EP Series Resins Total Energy, in/lb f F (38 C) -2 F (-29 C) 73 F (23 C) Melt Flow Rate, g/ min Figure Instrumented Dart Impact versus Thickness, CALIBRE 3 EP 22 MFR Resin Total Energy, in/lb f unaged and aged F (2 C) () (.5) (.) (.52) (2.3) (2.54) (5) (3.56) (4.6) (4.57) (5.8) Sample Thickness, inches (mm) J J 4

16 CALIBRE Polycarbonate Resins Properties and Performance For a CALIBRE resin of a given melt flow rate, the total energy value required to produce a fracture remains essentially the same across the temperature range of -2 to F (-29 to 38 C). When instrumented dart impact strength is plotted against sample thickness, the total energy of the impact decreases linearly with sample thickness. However, all of the samples failed in a ductile manner. (There was no thickness at which the failure mechanism changed from ductile to brittle as there is when using notched Izod impact.) Figure illustrates the relationship between the total energy of the instrumented dart impact versus thickness for CALIBRE 3 EP 22 MFR resin. Data are shown for both unaged specimens and those aged 64 hours at 248 F (2 C). All impacts were ductile. The differences in energy and the changes in the mode of failure between the notched Izod and the instrumented dart impact tests stress the importance of completely understanding the test method and results. No one physical property test method, performed on a test specimen, can completely predict a fabricated part s performance. Test data should be used for initial material screening and to understand material behavior under the test conditions. 5

17 CALIBRE Polycarbonate Resins Properties and Performance Tensile Strength Tensile properties provide an important indication of a material s strength. They are a measure of the force required to pull the resin apart, and of the amount of stretching it can withstand before breaking. Tensile properties are calculated from a stress-strain plot. A typical stress-strain curve for CALIBRE polycarbonate resin is shown in Figure. The data were generated according to ASTM D 638. Ultimate tensile strength is the maximum stress a material can withstand at the point of rupture. Yield tensile strength is stress at which non-elastic deformation begins or where an increase in strain occurs without an increase in stress at the yield point. Ultimate elongation is the total elongation of the sample at the point of rupture. The modulus of elasticity is the ratio of stress to strain in the elastic region. The area under the curve of a stress-strain diagram indicates the relative toughness of a material. CALIBRE resins have a high tensile yield strength, a high ultimate tensile strength and a high ultimate elongation. They therefore have a Figure Stress-Strain Plot at 73 F (23 C), CALIBRE 3 Series Resins Increasing Stress Yield Point Elastic Region Plastic Region Increasing Strain large stress-strain area, which is indicative of high toughness. CALIBRE polycarbonate resins are among the toughest engineering thermoplastics. The yield tensile strength, ultimate tensile strength and tensile modulus for CALIBRE polycar- Ultimate Strength Point of Rupture Figure 2 Yield Tensile Strength at Various Temperatures, CALIBRE 3 Series Resins Yield Tensile Strength, psi x (-8) 2 (-7) 4 (4) 6 (6) 8 (27) Temperature, F ( C) (38) 5 MFR 4 MFR 2 (49) (6) MPa bonate resins are relatively constant, showing no significant change over the range of commercially available MFRs. However, these properties do decrease with increasing temperature. Figure 2 indicates how yield tensile strength values are affected by changes in temperature. 6

18 CALIBRE Polycarbonate Resins Properties and Performance Thermal Properties As previously noted, high heat resistance is a distinguishing characteristic of CALIBRE polycarbonate resins. For an indication of temperature limits for molded parts, two test methods are used Deflection Temperature Under Load (DTUL) and Vicat Softening Point. High DTUL and Vicat Softening Point values make CALIBRE resins an ideal choice for many parts requiring high thermal stability. Deflection Temperature Under Load DTUL is measured according to ASTM D 648. The results relate to use temperatures under load and also are a measure of rigidity at service temperatures. DTUL measurements are affected by specimen molding conditions and therefore should be used for screening purposes only and not for direct measurement of specific structural properties of a part, nor for identifying upper limits of a useful temperature range. The typical DTUL of CALIBRE polycarbonate resins 258 to 27 F (26 to 32 C) is valid across the full range of melt flow rates. This data was obtained with unannealed, injection-molded specimens.25 inch (3.2 mm) thick, under load of 264 psi (.8 MPa). Vicat Softening Point Vicat Softening Point is determined according to ASTM D 525. Vicat temperatures are generally higher than DTUL temperatures. Measurements of Vicat are more indicative of a polymer s actual softening point than is DTUL, and are not usually affected by specimen molding conditions. The high Vicat of CALIBRE resins is retained throughout the melt flow rate range, decreasing only slightly from 34 F (5 C) to 297 F (47 C) for melt flow rates of 4 to 22. In addition, low Mold Shrinkage (.5-.7 in/in [.5-.7 mm/mm]) and Coefficient of Linear Thermal Expansion (38 x -6 in/in/ F [68 x -6 mm/mm/ C]) make CALIBRE polycarbonate resins the material of choice for applications requiring tight tolerances at elevated temperatures. 7

19 CALIBRE Polycarbonate Resins Properties and Performance Optical Properties The excellent optical properties and toughness of CALIBRE resins allow their use in applications requiring good transparency and high impact strength. The refractive index and light transmission of CALIBRE polycarbonate resins are compared with those of other transparent materials in Table 3. CALIBRE resins exhibit waterwhite clarity with visible light transmission averaging 89 percent. In addition, haze is minimal at approximately one percent. Electrical Properties The electrical properties of CALIBRE polycarbonate resins make them desirable for electrical and electronic applications. Their excellent electrical insulation properties are complemented by transparency and mechanical strength over a wide temperature range a combination not found in most other thermoplastics. Further, with CALIBRE resins, these electrical properties are not significantly affected by moisture or by the melt flow rate of the resin. Basic electrical properties for CALIBRE polycarbonate resins are shown in Table 4. Table 3 Optical Properties () of Transparent Materials ASTM TYRIL* Polymethyl- Cellulose CALIBRE Property Method Glass SAN methacrylate acetate polycarbonate Refractive Index D Light Transmission D () Typical property values; not to be construed as specifications. * Trademark of The Dow Chemical Company. Table 4 Electrical Properties () of CALIBRE Polycarbonate Resins at 73 F (23 C) ASTM Property Value Method Dielectric Strength, D mils (3.8 mm) 8 mils (2.3 mm) 2 mils (.5 mm) Volume Resistivity, D 257 ohm-cm 2. x 7 Surface Resistivity, D 257 ohms.88 x 3 Dielectric Constant D -,, Hz Dissipation Factor D -,, Hz < () Typical property values; not to be construed as specifications. 8

20 CALIBRE Polycarbonate Resins Properties and Performance Additional Performance Properties With Dow s state-of-the-art compounding technology, the broad family of CALIBRE polycarbonate resins can be formulated to meet special performance needs from color, ignition resistance and mold release; to enhanced impact, thermal and UV-stabilized performance. Colorants CALIBRE resins can be made available in the color or tint of your choice. To assure the highest possible retention of properties, coloring is done at our state-ofthe-art compounding facility. Standard colors and tints, and the availability of custom color/tint formulations, vary from series to series. Figures 3-5 show the results of impact tests comparing natural and colored CALIBRE resins. In Figure 3, the notched Izod value is plotted against the lower melt flow rate resins for three different systems: natural resin with no colorants; a white resin pigmented with TiO 2 ; and a black Figure 3 Notched Izod versus Melt Flow Rate, CALIBRE 3 Series Resins (Natural and Pigmented) Notched Izod, ft-lb/in Natural.5% Carbon Black % TiO Melt Flow Rate, g/ min Figure 4 Instrumented Dart Impact Total Energy Absorbed versus Melt Flow Rate, CALIBRE 3 and 3 EP Series Resins (Natural and Pigmented) Energy, ft-lb f % Carbon Black % TiO resin pigmented with carbon black. The resin pigmented with carbon black behaved identically to the natural resin, while the higher pigment loading and larger particle size of the TiO 2 colorant lowered the Izod values slightly. Natural Melt Flow Rate, g/ min J/m J Figure 4 shows that CALIBRE resins retain their inherently high impact strength in colored systems across the entire melt flow rate range of 3 MFR to 22 MFR, as measured by the instrumented dart impact test. 9

21 CALIBRE Polycarbonate Resins Properties and Performance Figure 5 illustrates the relative notch sensitivity of typical colored resins in CALIBRE 3 MFR resin. The data show that colorants increase the sensitivity to sharper notches over natural, unpigmented resins. Although pigments may tend to raise the DTUL, properly selected and compounded colorants typically have little effect on the thermal properties of CALIBRE resins. However, pigmentation generally lowers tensile properties in proportion to the amount of pigment used. Improved Flexural Properties CALIBRE polycarbonate resins have a typical flexural strength of 4, psi (96 MPa) and a typical flexural modulus of Figure 5 Notched Izod versus Notch Radius, CALIBRE 3 MFR Resin (Natural and Pigmented) Notched Izod, ft-lb/in Natural White Black , psi (2,4 MPa). These values, which are independent of MFR, can be increased significantly through the addition of glass fiber reinforcement. For example, CALIBRE 5 resin a percent glass-filled polycarbonate has a flexural modulus Notch Radii, mils J/m of 46, psi (3,7 MPa). In addition, glass-reinforcement generally reduces mold shrinkage; and while the practical, instrumented dart impact strength is retained, the notched Izod value drops to about.5 ft-lb/in (8 J/m). 2

22 CALIBRE Polycarbonate Resins Properties and Performance Ignition Resistance Several ignition-resistant (IR) CALIBRE resins are available to meet various industry requirements for ignition resistance, while maintaining toughness, strength and heat resistance. Also, ignition-resistant CALIBRE resins are available in both transparent and opaque formulations, with ratings of V- () and 5VA () as rated by Underwriters Laboratories Standard 94. All ignition-resistant formulations retain high instrumented dart impact strength across the entire range of melt flow rates. Figure 6 shows the -mil notched Izod impact strength versus melt flow rate for the 7 and 89 Series of ignition-resistant and superior ignition-resistance CALIBRE resins, compared with 3 Series general purpose CALIBRE resins. () CALIBRE polycarbonate resins containing ignitionresistant additives do not readily support ignition. However, they will burn under the right conditions of heat and oxygen supply. The resins should not be exposed to direct flame or extreme heat. Results of small-scale flammability tests on these or any other materials are not to be considered indicative of the behavior of these materials under actual fire conditions. Figure 6 Notched Izod Impact versus Melt Flow Rate, CALIBRE 3, 3 EP, 7 and 89 Series Resins (Natural and Pigmented) Izod Impact Strength, ft-lb/in CALIBRE 3, Natural CALIBRE 7, % TiO 2 CALIBRE 7, Natural CALIBRE 89, % TiO Melt Flow Rate, g/ min J/m 2

23 CALIBRE Polycarbonate Resins Properties and Performance Careful compounding permits all 7 Series resins and the 89 MFR resins to retain high Izod impact strength. CALIBRE 89 9 MFR resins generally have low -mil notched Izod values, but do maintain high practical or instrumented dart toughness. Often, applications using CALIBRE 89 9 MFR resins require the easier processability of the high melt flow rate over the high Izod specification. The practical toughness of the CALIBRE 89 9 MFR resins is generally adequate and meets overall strength requirements. Figure 7 shows that the thermal properties of CALIBRE 7 and 89 Series resins are comparable to those of CALIBRE 3 Series general purpose resins across the entire melt flow rate range. In addition, the limiting oxygen index (LOI) for CALIBRE 3 Series resins is 26 percent. For 7 Series resins, it is 4 percent, and for the 89 Series resins, it is 4 percent. Figure 7 Deflection Temperature Under Load versus Melt Flow Rate, CALIBRE 3, 7 and 89 Series Resins (Natural and Pigmented) 35 CALIBRE 7, Natural DTUL, F 3 25 CALIBRE 89, % TiO 2 5 DTUL, C CALIBRE 3, Natural Melt Flow Rate, g/ min 22

24 CALIBRE Polycarbonate Resins Properties and Performance Mold Release CALIBRE polycarbonate resins can be specially formulated to provide enhanced mold release performance, while maintaining the balance of resin properties. Refer to page 7 and consult Dow s technical service staff for additional information. UV Stabilizers and Weatherability Depending on your particular needs, CALIBRE polycarbonate resins are available with UV stabilizers (). In fact, CALIBRE resins are excellent materials for molded parts requiring a high degree of resistance to UV light from either indoor or outdoor sources. CALIBRE resins without UV stabilizers pass the accelerated indoor colorfast tests described by ASTM D 49, which simulate a three- to five-year exposure in an indoor office environment. In CALIBRE resins tested under these conditions, the change in color as measured by Delta E is typically less than two units. Table 5 Arizona Outdoor Exposure (), CALIBRE 3 Series Resins Izod CALIBRE Impact, % YI (3) Resin Time ft-lb/in %T (2) Haze Increase 3 6 MFR without UV Stabilizer 32 6 MFR with UV Stabilizer For parts exposed to outdoor environments, CALIBRE polycarbonate resins are available with enhanced weathering resistance. These resins are designated by a 2 or 3 in the last digit of the product identification code ( i.e., 32 5 MFR or 73 5 MFR). Our UV-stabilized formulations can greatly extend retention of the key physical properties of CALIBRE resins. The data in months year years months years years () Typical values: not to be construed as specifications. (2) %T = % Light Transmission (3) YI = Yellowness Index Table 5 show the performance of CALIBRE 3 6 MFR resins (with and without UV stabilizers), exposed in Arizona at a angle facing south. This two-year exposure normally correlates with approximately five years of typical service. Similar data were obtained in Florida exposures. The data in the chart indicate the superior exterior performance of CALIBRE polycarbonate resins with UV stabilizers. () The addition of a UV stabilizer to a resin does not completely eliminate the effects of UV exposure. These effects may include color shift (yellowing, darkening or bleaching), decreased ductility, decreased impact resistance, decreased mechanical properties, decreased surface gloss, and/or increased haze. The purpose of a UV stabilization package is to slow down the rate at which these effects occur. Actual results may vary depending on application and other factors such as resin color, transparency and additives. Therefore, actual enduse testing is recommended. 23

25 CALIBRE Polycarbonate Resins Properties and Performance Chemical Resistance Water is the chemical to which fabricated products are exposed most frequently. Water and high temperatures such as those used during processing can cause hydrolytic degradation by attacking the carbonate linkages, breaking the polycarbonate polymer chain, and lowering impact and tensile strength. As with most chemical reactions, the rate of attack depends on time and temperature. At standard room temperatures, there is no noticeable loss of properties after many years of contact with water. Contact with water at 4 F (6 C) and intermittent contact at temperatures up to 22 F ( C) may have little effect on properties. Severe conditions, such as those in steam autoclaves, however, may alter the clarity and toughness of the polymer faster. Therefore, the use of polycarbonate in such applications is limited and dependent on the autoclave cycle time and temperature. Because the primary effect of hydrolysis is reduction of molecular weight, selection of a low melt flow rate (high molecular weight) CALIBRE polycarbonate resin will assure the greatest possible retention of resin properties. This is why proper drying of polycarbonate resins is critical in obtaining the best performance from the polymer. For specific information on drying, refer to the Processing Guidelines section (page 29). Reagents The chemical resistance of polycarbonate resins is dependent on overall stress, which is a combination of part design, fabrication conditions and chemical and physical environments. CALIBRE polycarbonate resins are resistant to dilute mineral and organic acids, animal and vegetable oils and fats and alcohols. Dilute alkaline solutions of sodium carbonate and bicarbonate produce no effect, but ammonium hydroxide and amines degrade the polymer. Exposure to aromatic and halogenated hydrocarbons should be avoided as these are excellent solvents for polycarbonates. The information provided in Table 6 is a brief general guide to the chemical resistance of CALIBRE resins. Testing was conducted using ASTM D 543 and other similar methods in which product specimens with low internal stresses are weighed and tested for tensile strength, then immersed in the reagent for a period of 8 days. Upon removal, any changes in weight and/or tensile strength are recorded, with resistance ratings defined as follows: Good Little or no reduction in physical properties; change in weight under one percent and change in tensile strength under five percent. 24

26 CALIBRE Polycarbonate Resins Properties and Performance Fair Some reduction in physical properties occurs after long exposure, with either a change in weight of more than one percent or a change in tensile strength of more than five percent. Poor Significant changes in physical properties after short exposure to the substance, with both a change in weight of more than one percent and a change in tensile strength of more than five percent. Use of CALIBRE polycarbonate resins is not recommended in these applications. NOTE: Ratings listed are only indications and should not be interpreted as absolute proof of resistance of any part against a certain reagent. Testing of the actual parts under actual conditions of exposure is recommended to provide a more accurate indication of performance. Table 6 Chemical Resistance Ratings of CALIBRE Polycarbonate Resins at 73 F (23 C), 5% RH General Reagents Acids, dilute Acids, concentrated Alkalis Organic solvents Alcohols Chlorinated hydrocarbons Aromatic hydrocarbons Aliphatic hydrocarbons Cooking oils Lubricating oils Photochemicals Detergents Esters Ketones Phenols Salts Acidic Basic Neutral Specific Reagents Resistance Rating Good Fair-Good Poor-Fair Good Poor Poor Poor-Fair Good Good Good Good Poor Poor Good Good Fair Good Resistance Rating Zinc stearate Poor Ethylene glycol Good Methanol, ethanol Good Acetone Poor Motor oil Good Gasoline Fair Brake fluid Poor Methylene chloride Poor () Trichloroethane Poor () () Acts as a solvent for polycarbonate. 25

27 CALIBRE Polycarbonate Resins Properties and Performance Agency Compliance Food and Drug Administration (FDA) CALIBRE 2 Series resins, when used unmodified for the manufacture of food contact articles, will comply with the U.S. Food, Drug and Cosmetic Act, as amended, under Food Additive Regulation 2 CFR These resins include only such adjuvants and minor modifiers that are () permitted by 77.58, (2) permitted by other applicable FDA regulations, (3) generally recognized as safe, (4) used in accordance with a prior sanction or approval, or (5) have been shown by extraction and analytical testing not to be food additives. These resins meet the extractive limitation specified in The uses cited above are subject to good manufacturing practices and any limitations that are part of the regulations. These regulations should be consulted for complete details. The principles of FDA Good Manufacturing Practices are followed in the manufacture of selected CALIBRE resins. (For more information, call DOW (4369). In Mexico, call ). CALIBRE 2 Series health care resins have also undergone standard biocompatibility testing as outlined in United States Pharmacopoeia (USP) XXIII, Class VI, Biological Tests for Plastics. National Sanitation Foundation (NSF) Selected CALIBRE 2 Series resins are listed by the NSF under Standard 5, Plastic Materials and Components Used in Food Equipment. This listing includes natural and some standard tints, across a broad range of melt flow rates. Listing of additional custom colors may be obtained on request. Underwriters Laboratories (UL) Underwriters Laboratories investigate products and components of products to identify certain hazards affecting life and property. The investigation of plastic materials is done by conducting standardized tests categorizing the plastic material s physical, electrical and flammability properties. Many CALIBRE resins are listed in the UL Recognized Component Directory and on yellow cards that are available on request. Canadian Standards Association (CSA) CSA also tests products and components according to standards to help ascertain their suitability for use in given applications. Many CALIBRE resins are listed with CSA in their Plastics Components Acceptance Directory. The Dow Chemical Company maintains ongoing relationships with the agencies and organizations discussed here, as well as with other similar agencies and organizations in the United States and throughout the world. For additional information about individual resins, call DOW (4369). In Mexico, call

28 CALIBRE Polycarbonate Resins Processing Guidelines Processing Guidelines The Quiet One, a low-profile room air conditioner housed entirely in plastic, has been introduced under the brand names of White Westinghouse Mobilaire and Gibson Panorama trademarks. The use of CALIBRE polycarbonate resin, in place of the traditional metal housing, has resulted in increased functionality, cost efficiency and aesthetic appearance. (Photo Courtesy of Frigidaire Company.) Injection Molding The family of CALIBRE polycarbonate resins can be fabricated on conventional equipment, by the established techniques practiced by the plastics industry. Injection molding of CALIBRE resins is readily accomplished with most types of injection molding machines. Regardless of which type of machine you re using, the information in this section may be helpful in obtaining optimum results from the polymer selected. The tooling and equipment manufacturer should be consulted for the best selection of equipment capabilities and materials of construction. The selection needs to be made with consideration of resin grade, processing and handling conditions, tool design and finish, and production volume and rates. Several factors must be considered when fabricating CALIBRE polycarbonate resins into parts by injection molding: resin drying, machine selection and molding conditions. Importance of Drying Inadequate drying before processing is the most common cause of failure in attaining the highperformance properties inherent in polycarbonates. Polycarbonate 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 polycarbonate resins, moisture levels that cause no visual flaws can nevertheless cause severe degradation within the molded part. Even small amounts of water can attack the carbonate linkage of the polymer and bring about chain scission and lowered molecular weight, resulting in the loss of physical properties. The greater the amount of water in the resin during processing, the greater the loss of properties. Therefore, it is recommended that resin moisture content be limited to.2 percent when processing CALIBRE polycarbonate resins. 27

29 CALIBRE Polycarbonate Resins Processing Guidelines Drying Conditions Up to.35 percent moisture can be contained uniformly throughout the resin granule to be dried. Effective removal of that moisture depends on two conditions:. A dry air environment in which granules can reach equilibrium at a low moisture level. 2. High temperatures to drive the moisture out of the granules in a reasonable period of time. Drying at too low a temperature is a common cause of insufficient drying. Other factors that effect resin drying are the starting moisture level, granule size and shape, and drying residence time. Relative humidity is the ratio of the amount of water in the air to the amount of water needed to saturate the air at a given temperature. Dew point is defined as the temperature to which air containing a specified water content would have to be cooled to reach percent relative humidity. The dew point of the air in the drying equipment determines the degree of resin dryness that can be reached. Prolonged hot-air drying with air at too high a dew point will result in inadequate drying. Lowering the dew point does not reduce drying time significantly, but it is required for achieving adequate dryness of the resin. The volume of air passing through the dryer has a direct effect on drying rates. Hot air entering the dryer is the only source of heat to dry the granules and is the vehicle that carries away the moisture. Low air velocities delay the rise in granule temperature, and increase the bottom-to-top temperature differential within the dryer. Air flow insufficient to take moisture out of the dryer can actually increase the moisture content of granules at the top of the dryer by increasing that area s relative humidity. Virgin granules of CALIBRE polycarbonate resin are quite similar in size and shape and therefore tend to have uniform drying time. However, the use of regrind commonly introduces substantially larger granules to the resin mix. This can result in an increase in the drying time required. Drying Equipment Dryers that incorporate dehumidifying units are recommended for drying granules of CALIBRE polycarbonate resin. Operating conditions suggested by manufacturers of dryers may differ from one unit to another. Dow recommends three hours at 25 F (2 C) as minimum drying conditions for CALIBRE resins dried in dehumidifying dryers. Using Regrind Trim or scrap from fabrication of CALIBRE polycarbonate resins can be reground and reused if care is taken to avoid contamination and moisture pickup. Like virgin resin, regrind must be dried to a moisture content of. to.2 percent before use drying at 25 F (2 C) for five to six hours is recommended. Large particle sizes of regrind may require longer drying times. However, parts that were rejected because they were molded with wet resin cannot be reground and reused as the polymer has already been degraded. 28

30 CALIBRE Polycarbonate Resins Processing Guidelines Regrind can generally be used with virgin material in proportions of 25:75 for unfilled resins and :9 for glass-filled resins, with minimal loss of physical properties and color shift. The size of the regrind particle should be kept below.3 inch (8 mm). It also is important to minimize the amount of fines. Additional recommendations regarding specific resins and applications can be obtained by contacting your Dow TS&D representative. Machine Selection Clamp Tonnage The recommended clamp tonnage for CALIBRE 2, 3, 3 EP, 7 and 89 Series resins is three to five tons per square inch of projected part area. The glass-reinforced resins require higher clamp tonnage four to six tons per square inch because of their higher viscosity. Machine Capacity 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 2 and 75 percent of the total capacity. An optimum shot size is between 4 and 6 percent of machine capacity. The use of vented barrels on injection molding machines is not recommended for processing CALIBRE polycarbonate resins. Screw Selection There are three general guidelines for selection of the screw for an injection molding machine to be used with CALIBRE polycarbonate resin:. A minimum of 5: length-todiameter ratio. 2. A compression ratio between.5: and :. 3. Use of a slip-ring type nonreturn valve with clearances of at least.25 inch (3.2 mm) and a ring movement of at least.9 inch (4.8 mm). Molding Conditions Melt and Mold Temperatures 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. Generally, barrel temperature controllers should be PID type, and set so the material melts gradually, with cooler rear zone and hotter front zone 29

31 CALIBRE Polycarbonate Resins Processing Guidelines temperatures. 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 let down (L/D) ratios. Because machine set points and actual melt temperature often vary by as much as +/- 5 F (+/- 27 C), actual measurement of the melt temperature is recommended to verify that it falls within the recommended range. Keeping a uniform melt temperature within the recommended range is essential to ensure good color matching of mating component parts. Higher melt temperatures reduce the viscosity of the material and allow the material to flow easier. Melt temperatures in the upper end of the recommended range may be necessary when processing thin walled 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. Generally, cooling time is the rate-determining factor for overall cycle time. To obtain the best part properties and consistent dimensional tolerances, uniform heat removal is critical. Using a mold temperature controller will minimize temperature variations. Cooling lines should be properly placed and spaced around the part for effective heat removal. The cooling lines should be adequately sized, without restrictions in the connectors or associated piping. The flow rate of the cooling medium should be sufficient to provide for turbulent flow through the cooling lines. Cleanliness of the cooling medium should also be maintained to prevent blockage of the cooling lines. 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 walled parts and parts with long flow lengths. Lower mold temperatures allow the molten polymer to set up faster to reduce the overall cycle time. CALIBRE 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. Table 7 shows the suggested Injection Molding Conditions for processing CALIBRE polycarbonate resins of various melt flow rates. 3

32 CALIBRE Polycarbonate Resins Processing Guidelines Table 7 Suggested Injection Molding Conditions for CALIBRE Resins 8 MFR Glass- Parameters 3 MFR 6 MFR MFR 5 MFR 22 MFR (Audio CD) Reinforced Temperature. F ( C) Barrel Nozzle 6-64 F F 55-6 F F 5-53 F F 55-6 F ( C) ( C) ( C) ( C) ( C) (3-332 C) ( C) Front 6-64 F F 55-6 F F 5-53 F F 55-6 F ( C) ( C) ( C) ( C) ( C) (3-332 C) ( C) Intermediate F F 5-55 F 5-54 F F F F (293-3 C) ( C) ( C) ( C) ( C) (3-32 C) ( C) Rear (Hopper) F F 5-52 F F 47-5 F F F ( C) (27-29 C) ( C) ( C) ( C) (275-3 C) ( C) Mold 8-24 F 7-23 F 6-22 F 6-2 F 6-2 F 4-23 F 8-24 F (82-6 C) (77- C) (7-4 C) (7-93 C) (7-93 C) (56- C) (82-6 C) Manifold 6-64 F F 55-6 F F 5-53 F F 55-6 F ( C) ( C) ( C) ( C) ( C) ( C) ( C) Melt (Air Shot) 6-64 F F 55-6 F F 5-53 F F 55-6 F ( C) ( C) ( C) ( C) ( C) ( C) ( C) Pressure (psi) Back Injection Adjust to Control Part Weight and Dimensions Hold/Pack Cavity (x 3 ) (End of fill) Clamp Force, in Projected Area (Tons) Drying Time (Hours) Temperature ( F) Maximum Moisture, % (equilibrium level =.35%) Rate of Injection Speed Adjust to Control Appearance Annealing Ratios Screw Compression Ratio.5-/.5-/.5-/.5-/.5-/.5-/.5-/ Screw L/D Ratio Min 2/ Min 2/ Min 2/ Min 2/ Min 2/ Min 2/ Min 2/ Mold Shrinkage (mils per inch) 3 /.2 Kg) 3

33 CALIBRE Polycarbonate Resins Processing Guidelines Screw Speed A moderate screw speed of 4 to 7 rpm is recommended for CALIBRE 2, 3, 3 EP, IM 4, 7, 89 and 2 Series resins. For glass-reinforced resins (5 and 7 Series), a higher screw speed of 6 to 8 rpm is suggested. Specific machine limits due to machine and screw design differences may require operation outside these recommendations. Fill Pressure It is generally an advantage to fill the mold as rapidly as possible. Therefore, set the fill pressure as high as is practical. CALIBRE polycarbonate resins have been successfully processed at injection pressures as high as 34, psig. Back Pressure Machine back pressure should be set as low as is practical. Due to the excellent rheological properties of CALIBRE resins, a low back pressure is sufficient to plasticate the resin and produce a uniform polymer melt. Injection Speed The appropriate injection speed for CALIBRE polycarbonate resins is determined largely by gate design. Polycarbonate resins are susceptible to formation of gate blush in small or edge gates. For parts made with these types of gates, it is important to run the injection machine at as slow an injection speed as possible. For other types of gates, a faster injection speed may be used. Melt Cushion The use of a cushion or residual polymer melt in the barrel after injection, will help ensure that the proper amount of material is injected into the cavity. 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 bottom-out, 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. This will minimize the residence time and heat history of the polymer, reducing the potential for polymer degradation. 32

34 CALIBRE Polycarbonate Resins Processing Guidelines General Rules for Effective Troubleshooting CALIBRE polycarbonate resins are proven materials that can be quickly and easily injection molded into quality parts with excellent aesthetics and physical properties. While molding problems do occasionally occur, most are readily resolved or prevented with attention to the following recommendations. Understand the Process and Product A thorough understanding of both the theory and mechanics of the injection molding process and of the machinery and other equipment employed is essential to trouble-free operation. This also applies to the particular resins being processed. Operators should be reasonably familiar with the chemical, physical and mechanical properties of these materials and should be able to anticipate the probable behavior of the resin under varying heat and pressure conditions. Anticipating potential problems and correcting them before they occur can significantly shorten start-up and production times. Change Only One Control or Condition at a Time This may seem obvious, but experience suggests that this is the one rule most often neglected. Clearly, if more than one control is changed at a time, there is no way to monitor which control was responsible for the change in the machine operation. Allow Sufficient Time for a Change to Take Effect Allow sufficient time (i.e., shots) after each change for the material and the machine to adjust and reach equilibrium. Obviously, if sufficient time is not allowed before additional changes are made, there will be no way to accurately monitor whether or not a particular change was effective. Sufficient time depends on the nature of the control or other factor that was changed, the shot size (especially in relation to the barrel capacity), and the length or complexity of the overall cycle. Keep an Accurate Record or Log of Each Change Keeping an accurate and detailed log of each change and saving it as a permanent record of the total job is an excellent practice. This record should include the machine number, the material or resin lot numbers, machine conditions and performance, mold and part identification numbers, etc. Such a record can be very helpful the next time the same machine, mold or material is used. This record can also be extremely useful in preparing future cost estimates for molded parts. Provide Clear, Written Instructions Once a solution to a problem has been found, post clear, written instructions on or near the machine in question. Also, enter these instructions in the log or job history. 33

35 CALIBRE Polycarbonate Resins Processing Guidelines Table 8 Injection Molding Troubleshooting Guide Black Specks Purge the machine according to purging recommendations Burn Marks Decrease nozzle temperature Decrease injection speed Decrease booster time Decrease injection pressure Improve mold cavity venting Alter gate position and/or increase gate size Check for heater malfunction Discoloration Purge heating cylinder Lower material temperature Lower nozzle temperature Shorten overall cycle Check hopper and feed zone for contaminants Provide additional vents in mold Move mold to smaller shot size press Jetting Decrease injection speed Increase resin and/or mold temperature Increase gate size Part Brittleness Check to be sure material is dried Check for contamination Decrease amount of regrind Avoid excessive processing temperature Check for heat malfunction Sinks and/or Voids Increase injection pressure Increase injection hold time Increase injection speed (for sinks); decrease injection speed (for voids) Raise mold temperature (for voids); lower mold temperature (for sinks) Increase stock temperature (for sinks); decrease stock temperature (for voids) Increase size of sprue and/or runners and/or gates Sticking in Cavity Decrease injection pressure Decrease injection hold Decrease booster time Increase mold-closed time Lower cavity temperature Decrease cylinder and nozzle temperature Check mold for undercuts and/or insufficient draft Sticking on Core Decrease injection pressure Decrease injection hold Decrease booster time Decrease mold-closed time Increase core temperature Decrease cylinder and nozzle temperature Check mold for undercuts and/or insufficient draft Splay Marks, Silver Streaks, Splash Marks Dry material before use Check for contamination Lower material temperature Lower nozzle temperature Shorten overall cycle Decrease injection speed Raise mold temperature Open the gates Increase back pressure Decrease decompression Warpage, Part Distortion Equalize cooling rate of both halves of mold by adjusting control temperatures Check handling of parts after ejection from mold Increase injection hold and mold-closed time Lower material temperature Jig the part and cool uniformly Weld Lines Increase injection pressure Increase injection speed Increase injection hold time Raise mold temperature Raise material temperature Clean vents Vent the cavity in the weld area Change gate location to alter flow pattern 34

36 CALIBRE Polycarbonate Resins Processing Guidelines Extrusion CALIBRE polycarbonate resins are readily extruded. High-quality sheet, thin films and profiles can be successfully extruded on standard single-screw machines. Most CALIBRE resins can be extruded, but higher molecular weight (low melt flow rate) resins are recommended. The high melt viscosity of such resins helps produce well-mixed, homogeneous melts. Extruders for polycarbonate should have a length-to-diameter ratio of at least 2:. Larger (32: l/d) machines can both increase production output and improve melt uniformity. Many different designs of extrusion screws perform adequately in melting, mixing and pumping CALIBRE polycarbonate resins. Best results often are achieved with general purpose, metering-type screws. Compression ratios from 2.5: to : are favored with a long, gradual transition from the feed to the metering section. Figure 8 Typical Single-Stage Extruder Screw Design and Conditions for Use with CALIBRE Polycarbonate Resins Hopper Feed Zone F ( C) (May need to be higher for low powered extruders) Length-to-Diameter Ratio 24: Compression Ratio 2.5:-: The wide processing temperature range of CALIBRE polycarbonate resins is an asset for successful extrusion. Operating conditions need to be set in accordance with extruder size and horsepower, screw design, screw speed and material selection. The most common extrusion temperatures are between 53 F and 6 F (277 and 36 C). Hopper Dryer 3 Hour Minimum Residence 25 F (2 C) Transition Zone F ( C) Metering Zone F ( C) Die Flights Feed 8 Transition 8 Metering 8 Die F ( C) The high processing temperatures used with CALIBRE resins make it necessary that the screw, barrel and die be given sufficient time to reach operating conditions. Once the set temperatures are reached, a one-hour soaking time should be allowed. Figure 8 shows typical extrusion conditions for a singlestage extruder screw design. 35

37 CALIBRE Polycarbonate Resins Processing Guidelines Table 9 Suggested Sheet Extrusion Conditions for CALIBRE Resins Glass- Parameters 3 MFR 6 MFR MFR Reinforced Temperature. F ( C) Melt Screw Cooling (Y/N) Y Y Y Y Barrel Feed Throat Full On Full On Full On Full On Rear (Hopper) F F F F ( C) ( C) ( C) ( C) Intermediate F F F F ( C) ( C) ( C) ( C) Front F F F F ( C) ( C) ( C) ( C) Chill Roll (H 2 ) 25-3 F 25-3 F 25-3 F 25-3 F (2-55 C) (2-55 C) (2-55 C) (2-55 C) Die F F F F ( C) ( C) ( C) ( C) Pressure (psi) Drying Time (Hours) Temperature F ( C) (2 C) (2 C) (2 C) (2 C) Maximum Moisture, % (equilibrium level =.35%) Distance Gaps (assume final sheet guage of X ) Die Gap X + 5% X + 5% X + 5% X + 5% Rollk Stack Gaps st NIP X X X X 2nd NIP X + % X + % X + % X + % Haul-Off Roll Gap X X X X Die Lip to First NIP Minimize Minimize Minimize Minimize Annealing 25 C for 3 minutes Ratios Screw L/D Ratio 24/-32: 24/-32: 24/-32: 24/-32: Screw Compression Ratio 2.5-/ 2.5-/ 2.5-/ 2.5-/ Geometry Screen Pack Meshes 2/6/8/2 2/6/8/2 2/6/8/2 2/6/8/2 3 /.2 Kg 36

38 CALIBRE Polycarbonate Resins Processing Guidelines In sheet extrusion operations, the use of conventional take-off systems has been very successful despite the higher temperature of the sheet produced. A variety of polishing-stack designs has been successfully used for polycarbonate sheet. Individually driven rolls, heated to between 25 and 3 F (2 and 54 C), have proven efficient in eliminating chatter lines. At thicker gauges, the toughness and ductility of the polycarbonate prevent shear-type cutting devices from making sharp, clean cuts. Traveling saws with carbide tips may be needed for efficient sheet cutting. Other Fabrication Technologies Injection Blow Molding Injection blow molding of CALIBRE polycarbonate resin is used to produce containers of all sizes, from one-oz. vials to gallon-size bottles. The procedure involves injection molding a preform, then blowing the finished article in a second mold. Injection blow molding provides tight neck tolerances and is especially suitable for largevolume production of small-size containers. Applications, not limited to bottles, include such diverse products as lighting globes and oil filter housings. Extrusion Blow Molding Extrusion blow molding permits production of larger containers than does injection blow molding. A tubular parison is extruded, clamped within the mold, and then is blown into the shape of the finished article. Extrusion can be continuous or intermittent. The particular type of extrusion blow molding machine required depends on the size and weight of the extruded parison, and on the size and shape of the finished article. The surfaces of the die and head effect the surface finishes of the complete product. 37

39 CALIBRE Polycarbonate Resins Processing Guidelines Chromium plating may help optimize appearance. A screw and die head standard for PVC fabrication are recommended for extrusion blow molding of CALIBRE polycarbonate resins. Films/Coextrusion In addition to the technologies discussed above, polycarbonate resins from Dow may be made into films, or can be coextruded in multi-layer structures. NOTE: Feedblock coextrusion is a patented, licensable technology of The Dow Chemical Company. Structural Foam Molding Structural foam molding of CALIBRE polycarbonate resins results in parts having reduced densities and excellent strength-toweight ratios. Either nitrogen or a chemical blowing agent may be used. The agent decomposes at the plasticizing temperature and causes the polymer to expand and fill the mold cavity. Parts can be molded using either low-pressure or highpressure processes. A key factor in structural foam molding of polycarbonate is achieving and maintaining uniform melt temperature to attain optimal melt viscosities for the desired flow lengths. To mold polycarbonate foam with conventional injection molding equipment, the only modification needed is a large bore shut-off nozzle. The latter seals the barrel, and prevents excessive drool resulting from blowing agent expansion. As with other processing technologies, proper resin drying is critical to successful use of structural foam CALIBRE polycarbonate resins. 38

40 CALIBRE Polycarbonate Resins Processing Guidelines Purging Both before and after CALIBRE polycarbonate resins are processed, the fabricating equipment must be thoroughly purged. An effective method of purging is to use a highheat, general purpose polystyrene. The unlubricated W granulation should be employed. For start-up purging, the polystyrene resin should be run through the machine at 4 to F (24 to 232 C) until clear. At that time, the zone heaters should be set to the temperatures needed to run CALIBRE resins. When the machine reaches operating temperature, purge with thoroughly dried CALIBRE resins until clear. After completing a run with CALIBRE resins, it is important that all of the polycarbonate be removed from the machine. One method to do this, using polystyrene resin, is outlined as follows:. While at polycarbonate operating temperatures, add to the hopper enough polystyrene resin for 2 to 3 shots. 2. Purge the polystyrene through the machine until the extrudate starts to swell significantly. 3. Set the temperatures of all zone heaters to 4 to F (24 to 232 C). 4. Continue purging until the melt temperature drops below 5 F (26 C) and the extrudate is clear. 5. Shut the machine down with the screw in the forward position. Finishing Parts fabricated from CALIBRE resins are readily finished or decorated by a variety of conventional methods. Techniques in wide use include painting, hot stamping and plating. 39

41 CALIBRE Polycarbonate Resins Appendix: Typical Properties Data Properties () Test Units 2 Series Method English (SI) Food Contact Resins 3 and 3 EP Series 3V Series IM 4 Series General Purpose Resins General Purpose Resins Impact Modified Resins PHYSICAL PROPERTIES 2 3 MFR 2 6 MFR 2 MFR 2 5 MFR 2 22 MFR 3 6 MFR 3 MFR 3 5 MFR 3 EP 22 MFR 3V 6 MFR 3V MFR 3V 5 MFR IM 4 MFR IM 4 8 MFR Specific Gravity D 792 g/cc (kg/m 3 ).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).8 (,8).8 (,8) Water 73 F (23 C), 24 hrs D F (23 C), Equilibrium D 57 % Mold Shrinkage D 955 in/in (mm/mm) OPTICAL PROPERTIES Refractive Index D 542 n D Haze D 3 % Light Transmission D 3 % MECHANICAL PROPERTIES Tensile Modulus (2) D 638 psi (MPa) 36, (2,48) 34, (2,34) 34, (2,34) 34, (2,34) 34, (2,34) Yield Stress D 638 psi (MPa) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8, (56) 8,4 (58) Ultimate Tensile Strength D 638 psi (MPa),5 (72),5 (72),3 (7),3 (7) 9,5 (66),5 (72),3 (7),3 (7) 9,5 (66),5 (72),3 (7),3 (7) Break D 638 % Flexural Modulus D 79 psi (MPa) 33, (2,27) 33, (2,27) Flexural Strength D 79 psi (MPa) 4, (96) 4, (96) 4, (96) 4, (96) 4,(96) 4, (96) 4, (96) 4, (96) 4, (96) 4, (96) 4, (96) 4, (96) 3, (9) 3, (9) Unnotched Izod Impact 73 F (23 C) D 256 ft-lb/in (J/m) No break No break No break No break No break No break No break No break No break No break No break No break Notched Izod Impact 73 F (23 C) (3) D 256 ft-lb/in (J/m) 8 (95) 7 (9) 7 (9) 6 (85) 4 (75) 7 (9) 7 (9) 6 (85) 4 (75) 7 (9) 7 (9) 6 (85) 3 (694) F (-3 C) D 256 ft-lb/in (J/m) (534) 7 (374) Instrumented Dart Impact, Total 73 F (23 C) (4) D 3763 in-lb (J) 83 (94) 8 (9) 77 (87) 77 (87) 64 (72) 8 (9) 77 (87) 77 (87) 64 (72) 8 (9) 77 (87) 77 (87) 5 (57) (9) (5) (9) Tensile Impact 73 F (23 C) (5) D 822 ft-lb/in 2 (kj/m 2 ) 3 (63) 28 (589) 25 (526) 22 (462) 8 (378) 28 (589) 25 (526) 22 (462) 8 (378) 28 (589) 25 (526) 22 (462) 3 (63) 28 (589) Rockwell Hardness D 785 R Scale (M Scale) 8 (74) 8 (73) 8 (73) 8 (72) 8 (72) 8 (73) 8 (73) 8 (72) 8 (72) 8 (73) 8 (73) 8 (72) Taber Abrasion Resistance Haze (6) D 44 % THERMAL PROPERTIES 66 psi (. MPa) annealed (7) D 648 F ( C) 295 (46) 293 () 29 (44) 289 (43) 288 (42) 293 () 29 (44) 289 (43) 288 (42) 293 () 29 (44) psi (.8 MPa) annealed (7) D 648 F ( C) 289 (43) 288 (42) 286 (4) 284 (4) 282 (39) 288 (42) 286 (4) 284 (4) 282 (39) 288 (42) 286 (4) 284 (4) 277 (36) psi (.8 MPa) unannealed (8) D 648 F ( C) 27 (32) 265 (29) 262 (28) 26 (27) 258 (26) 265 (29) 262 (28) 26 (27) 258 (26) 265 (29) 262 (28) 26 (27) 25 (2) 25 (2) Vicat Softening Point, 5 C/hr, 5N load D 525 F ( C) 34 (5) 34 (5) 3 (49) 298 (48) 297 (47) 34 (5) 3 (49) 298 (48) 297 (47) 34 (5) 3 (49) 298 (48) 295 (46) 295 (46) Coefficient of Linear Thermal Expansion D 696 in/in/ F (mm/mm/ C) 38 x x x x x x x x x x x x to 8 F (-4 to 82 C) RHEOLOGICAL PROPERTIES (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) Melt Flow Rate (MFR), 3 C/.2 kg D 238 g/ min ELECTRICAL PROPERTIES Dielectric Strength D 49 V/mil (kv/mm) 42 (7) 42 (7) 42 (7) 42 (7) 42 (7) 42 (7) 42 (7) 42 (7) 42 (7) 42 (7) 42 (7) 42 (7) Dielectric 6 Hz D MHz D 5 Dissipation 6 Hz D MHz D Volume 73 F (23 C), dry D 257 ohm-cm 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 IGNITION RESISTANCE () Flammability in (.6 mm) UL94 V-2 V-2 V-2 in (3.2 mm) UL94 V-2 V-2 V-2 V-2 Limiting Oxygen Index D 2863 % Average Extent of Burning D 635 in (mm) (25) (25) (25) (25) (25) (25) (25) (25) (25) (25) (25) (25) () Typical properties; not to be construed as specifications (2) 2 in/min (5 mm/min) (3).25 in; mil notch (3.2 mm;.25 mm notch) (4).25 in; 8, ipm (3.2 mm; 23 m/min) (5) Type S (6), g; CS-F wheel; 5 cycles (7) 7 in (4. mm) (8).25 in (3.2 mm) (9) Tested at. in (2.54 mm) thick, 5 mph () CALIBRE polycarbonate resins containing ignitionresistant additives do not readily support ignition. However, they will burn under the right conditions of heat and oxygen supply. The resins should not be exposed to direct flame or extreme heat. Results of small-scale flammability tests on these or any other other materials are not to be considered indicative of the behavior of these materials under actual fire conditions. 4 4

42 CALIBRE Polycarbonate Resins Appendix: Typical Properties Data Properties () Test Units 6 Series 7 Series Method English (SI) Branched Resins Ignition-Resistant Resins (9) 89 Series Superior Series Ignition Resistant Resins () Optical Media Resins 5 Series 7 Series Glass-Reinforced Resins Glass-Reinforced, Ignition-Resistant Resins PHYSICAL PROPERTIES 6 3 MFR 6 5 MFR 7 5 MFR 89 MFR 89 2 MFR 8 DVD 55 5 MFR 5 5 MFR 52 5 MFR SF 77 (9) 7 MFR.2 (,24) 7 5 MFR Specific Gravity D 792 g /cc (kg/m 3 ).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).23 (,27).27 (,27).3 (,326).27 (,27) Water 73 F (23 C), 24 hrs D F (23 C), Equilibrium D 57 % Mold Shrinkage D 955 in/in (mm/mm) OPTICAL PROPERTIES Refractive Index D 542 n D Haze D 3 % Light Transmission D 3 % MECHANICAL PROPERTIES , (2,275) Tensile Modulus (2) D 638 psi (MPa) 334, (2,3) 334, (2,3) 325, (2,24) 3, (2,38) 3, (2,38) 334, (2,3), (3,) 49, (3,38) 75, (5,7) 6,526 () 53, (3,65) Yield Stress D 638 psi (MPa) 8,7 (6) 8,7 (6) 8,8 (6) 8,9 (6) 8,9 (6) 8,7 (6) 9, (62) 9,5 (65) Ultimate Tensile Strength D 638 psi (MPa) 8,22 (56) 8,22 (56) 9,5 (66) 8,5 (59) 8,5 (59) 7, (48) 7, (48) 8,8 (6) 2, (83) 6 9, (63) Break D 638 % , (2,76) 4 Flexural Modulus D 79 psi (MPa) 34, (2,35) 334, (2,3) 338, (2,33) 338, (2,33) 363, (2,5) 46, (3,7) 7, (4,82) 2,5 (86) 55, (3,79) Flexural Strength D 79 psi (MPa) 3,6 (94) 3,6 (94) 4,5 () 4,2 (98) 4,2 (98) 4,5 () 3,6 (94) 2,5 (48) 5,8 (9) Unnotched Izod Impact 73 F (23 C) D 256 ft-lb/in (J/m) No break.747 (4).54 (29).747 (4) Notched Izod Impact 73 F (23 C) (3) D 256 ft-lb/in (J/m) 7 (89) 7 (89) 6 (854) 3 (694) 3 (694) 5 (27) 3 (6).5 (8) 2 (7) F (-3 C) D 256 ft-lb/in (J/m) 3.3 (76) Instrumented Dart Impact, Total 73 F (23 C) (4) D 3763 in-lb (J) 7 (79) 55 (62) 55 (62) 52 (59) 4 (46) 355 (4) 88 () 3 (34) Tensile Impact 73 F (23 C) (5) D 822 ft-lb/in 2 (kj/m 2 ) 25 (526) 22 (462) 8 (378) 3 (63) 28 (589) 7 (47) 7 (47) 7 (47) Rockwell Hardness D 785 R Scale (M Scale) 23 (59) 23 (59) 23 (59) 24 (58) 22 (62) 22 (62) 22 (62) Taber Abrasion Resistance Haze (6) D 44 % THERMAL PROPERTIES 66 psi (. MPa) annealed (7) D 648 F ( C) 279 (37) 279 (37) 278 (37) (9) 3 (49) 29 (44) 297 (47) 29 (43) psi (.8 MPa) annealed (7) D 648 F ( C) 275 (35) psi (.8 MPa) unannealed (8) D 648 F ( C) 259 (26) 259 (26) 26 (27) 26 (27) 26 (27) 256 (24) 285 (4) 273 (34) 28 (38) 273 (34) 285 (4) Vicat Softening Point, 5 C/hr, 5N load D 525 F ( C) 32 (5) 32 (5) 39 (54) 34 (5) 34 (5) 297 (47) 32 (6) 32 (6) 3 (54) 32 (6) Coefficient of Linear Thermal Expansion D 696 in/in/ F (mm/mm/ C) 38 x x x x x -6 2 x -6 2 x x -6 2 x -4 to 8 F (-4 to 82 C) RHEOLOGICAL PROPERTIES (68 x -6 ) (68 x -6 ) (68 x -6 ) (65 x -6 ) (65 x -6 ) () (38 x -6 ) (38 x -6 ) () (57 x -6 ) (38 x -6 ) Melt Flow Rate (MFR), 3 C/.2 kg D 238 g/ min ELECTRICAL PROPERTIES Dielectric Strength D 49 V/mil (kv/mm) Dielectric 6 Hz D MHz D 57 Dissipation 6 Hz D MHz D 5 Volume 73 F (23 C), dry D 257 ohm-cm IGNITION RESISTANCE () Flammability in (.6 mm) UL94 V-2 V- V- V-2 V-2 V-2 in (3.2 mm) UL94 V- V- V- V-2 V- V- V- (2) in (3.2 mm) UL94 5V 5VA 5VA 5VA (3) 5VA Limiting Oxygen Index D 2863 % Average Extent of Burning D 635 in (mm) (25) <.5 (3) <.5 (3) <.5 (3) 42 () Typical properties; not to be construed as specifications (2) 2 in/min (5 mm/min) (3).25 in; mil notch (3.2 mm;.25 mm notch) (4).25 in; 8, ipm (3.2 mm; 23 m/min) (5) Type S (6), g; CS-F wheel; 5 cycles (7) 7 in (4. mm) (8).25 in (3.2 mm) (9) Unannealed test sample () CALIBRE polycarbonate resins containing ignition-resistant additives do not readily support ignition. However, they will burn under the right conditions of heat and oxygen supply. The resins should not be exposed to direct flame or extreme heat. Results of small-scale flammability tests on these or any other other materials are not to be considered indicative of the behavior of these materials under actual fire conditions. () NOTICE REGARDING LONG-TERM MEDICAL IMPLANT APPLICATIONS: The Dow Chemical Company does not recommend any medical grade resin or film product for long-term medical implant applications in humans, i.e., for more than 72 hours (or 3 days, for PELLETHANE* polyurethane elastomers). Further, Dow does not recommend the use of any resin (or film) product for use in cardiac prosthetic devices regardless of the time period that the device will be wholly or partially implanted in the body. Such applications include, but are not limited to, pacemaker leads and devices, cardiac prosthetic devices such as artificial hearts, heart valves, intra-aortic balloons and control systems, and ventricular bypass assist devices. Dow does not recommend any nonmedical grade resin (or film) product for use in any human implant applications. *Trademark of The Dow Chemical Company. 43

43 CALIBRE Polycarbonate Resins Appendix: Typical Properties Data Properties () Test Units 2 Series Method English (SI) Health Care Resins () LG 223 MFR 26 6 MFR 26 MFR 26 5 MFR MFR 27 5 MFR MFR MegaRad 28 MFR MegaRad 28 5 MFR PHYSICAL PROPERTIES ) Specific Gravity D 792 g/cc (kg/m 3 ).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2).2 (,2) Water 73 F (23 C), 24 hrs D F (23 C), Equilibrium D 57 % Mold Shrinkage D 955 in/in (mm/mm) OPTICAL PROPERTIES Refractive Index D 542 n D Haze D 3 % Light Transmission D 3 % MECHANICAL PROPERTIES Tensile Modulus (2) D 638 psi (MPa) 34, (2,34) 34, (2,34) 34, (2,34) 34, (2,34) 32, (2,2) 32, (2,2) Yield Stress D 638 psi (MPa) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) 8,7 (6) Ultimate Tensile Strength D 638 psi (MPa),3 (7),5 (72),3 (7),3 (7) 9,5 (66),3 (7) 9,5 (66) 9,8 (67) 9,8 (67) Break D 638 % Flexural Modulus D 79 psi (MPa) Flexural Strength D 79 psi (MPa) 4, (96) 4, (96) 4, (96) 4, (96) 4, (96) 4, (96) 4, (96) 4, (96) Unnotched Izod Impact 73 F (23 C) D 256 ft-lb/in (J/m) No break No break No break No break No break No break No break No break No break Notched Izod Impact 73 F (23 C) (3) D 256 ft-lb/in (J/m) 7 (9) 7 (9) 7 (9) 6 (85) 4 (75) 6 (85) 4 (75) 4 (75) F (-3 C) D 256 ft-lb/in (J/m) Instrumented Dart Impact, Total 73 F (23 C) (4) D 3763 in-lb (J) 77 (87) 8 (9) 77 (87) 77 (87) 64 (72) 77 (87) 64 (72) 72 (8) 72 (8) Tensile Impact 73 F (23 C) (5) D 822 ft-lb/in 2 (kj/m 2 ) 25 (526) 28 (589) 25 (526) 22 (462) 8 (378) 22 (462) 8 (379) 8 (379) 8 (379) Rockwell Hardness D 785 R Scale (M Scale) 8 (73) 8 (73) 8 (73) 8 (73) 8 (73) 8 (73) 8 (73) 8 (73) 8 (73) Taber Abrasion Resistance Haze (6) D 44 % THERMAL PROPERTIES 66 psi (. MPa) annealed (7) D 648 F ( C) 29 (44) 293 () 29 (44) 289 (43) 288 (42) 289 (43) psi (.8 MPa) annealed (7) D 648 F ( C) 286 (4) 288 (42) 286 (4) 284 (4) 282 (39) 284 (4) psi (.8 MPa) unannealed (8) D 648 F ( C) 263 (28) 265 (29) 263 (28) 26 (27) 258 (26) 26 (27) 258 (26) 252 (22) 252 (22) Vicat Softening Point, 5 C/hr, 5N load D 525 F ( C) 32 (56) 34 (57) 32 (56) 39 (54) 36 (52) 39 (54) 36 (52) 298 (47) 298 (47) Coefficient of Linear Thermal Expansion D 696 in/in/ F (mm/mm/ C) 38 x x x x x x x x x -4 to 8 F (-4 to 82 C) RHEOLOGICAL PROPERTIES (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) (68 x -6 ) Melt Flow Rate (MFR), 3 C/.2 kg D 238 g/ min ELECTRICAL PROPERTIES Dielectric Strength D 49 V/mil (kv/mm) 42 (7) 399 (6) 42 (7) 42 (7) 42 (7) 42 (7) 399 (6) 42 (7) 42 (7) Dielectric 6 Hz D MHz D 57 Dissipation 6 Hz D MHz D Volume 73 F (23 C), dry D 257 ohm-cm 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 2. x 7 IGNITION RESISTANCE () Flammability in (.6 mm) in (3.2 mm) in (3.2 mm) UL94 5V Limiting Oxygen Index D 2863 % Average Extent of Burning D 635 in (mm) (25) (25) (25) (25) (25) (25) () Typical properties; not to be construed as specifications (2) 2 in/min (5 mm/min) (3).25 in; mil notch (3.2 mm;.25 mm notch) (4).25 in; 8, ipm (3.2 mm; 23 m/min) (5) Type S (6), g; CS-F wheel; 5 cycles (7) 7 in (4. mm) (8).25 in (3.2 mm) (9) Structural Foam formulation; tested at.25 in (6.4 mm) () CALIBRE polycarbonate resins containing ignitionresistant additives do not readily support ignition. However, they will burn under the right conditions of heat and oxygen supply. The resins should not be exposed to direct flame or extreme heat. Results of small-scale flammability tests on these or any other other materials are not to be considered indicative of the behavior of these materials under actual fire conditions. () NOTICE REGARDING LONG-TERM MEDICAL IMPLANT APPLICATIONS: The Dow Chemical Company does not recommend any medical grade resin or film product for long-term medical implant applications in humans, i.e., for more than 72 hours (or 3 days, for PELLETHANE polyurethane elastomers). Further, Dow does not recommend the use of any resin (or film) product for use in cardiac prosthetic devices regardless of the time period that the device will be wholly or partially implanted in the body. Such applications include, but are not limited to, pacemaker leads and devices, cardiac prosthetic devices such as artificial hearts, heart valves, intra-aortic balloons and control systems, and ventricular bypass assist devices. Dow does not recommend any nonmedical grade resin (or film) product for use in any human implant applications. (2) Tested at.49 in (3.73 mm) (3) 44 Tested at.248 in (6.3 mm)

44 CALIBRE Polycarbonate Resins Handling Considerations Handling Considerations Ethicon Endo-Surgery Inc., a Johnson & Johnson Company, employs CALIBRE polycarbonate resins for the rotation knob, handles and transparent spoon-like tips of its endoscopic vessel harvesting system. CALIBRE resins provide the strength, rigidity, optical properties and resistance to gamma sterilization required to make the system a success. Material Safety Data (MSD) sheets for CALIBRE polycarbonate resins are available from Dow Plastics, a business group of The Dow Chemical Company. MSD sheets are provided to help customers satisfy their own handling, safety and disposal needs, and those that may be required by OSHA and other applicable laws. MSD sheets are updated regularly, therefore, please request the most current MSD sheet before handling or using any product. The following comments are general and apply only to CALIBRE polycarbonate resins as supplied: Various additives and processing aids used in fabrication and other materials used in finishing steps have their own safe use profile and must be investigated separately. Hazards and Handling Precautions These resins may contain glass fibers as a reinforcing agent. CALIBRE polycarbonate resins have a very low degree of toxicity and under normal handling conditions of use should pose no unusual problems from ingestion, eye or skin contact. However, caution is advised when handling, 46

45 CALIBRE Polycarbonate Resins Handling Considerations storing, using or disposing of these resins and good housekeeping and controlling of dusts are necessary for safe handling of product. Workers should be protected from the possibility of contact with molten resin during fabrication. Handling and fabrication of plastic resins can result in the generation of vapors and dust, including small particles of glass fibers. Dusts resulting from sawing, filing and sanding of plastic parts in post-molding operations may cause irritation to eyes and the upper respiratory tract. In dusty atmospheres, use an approved dust respirator. Pellets or beads may present a slipping hazard. Slight itching and irritation may result from skin contact. Repeated exposure to particles generated by grinding glass fiber-reinforced materials may result in implantation of particles in the skin. Processing improperly dried resin can result in the production of bisphenol A. Good general ventilation of the processing area is recommended. Processing may release fumes which may include polymer fragments and other decomposition products. At temperatures exceeding melt temperature, polymer fragments can occur. Good general ventilation should be sufficient for most conditions. Local exhaust ventilation may be necessary for some operations. Use safety glasses. If there is a potential for exposure to particles which could cause mechanical injury to the eye, wear chemical goggles. If vapor exposure causes discomfort, use a full-face respirator. No other precautions other than clean, body-covering clothing should be needed for handling CALIBRE polycarbonate resins. Use gloves with insulation for thermal protection, when needed. Combustibility Although some resins may contain ignition-resistant chemical additives, CALIBRE polycarbonate resins will burn and, once ignited, may burn rapidly under the right conditions of heat and oxygen supply. Do not permit dust to accumulate. Dust layers can be ignited by spontaneous combustion and other ignition sources. When suspended in air, dust can pose an explosion hazard. Dense black smoke is produced when product burns. Toxic fumes are released in fire situations. Firefighters should wear positive-pressure, self-contained breathing apparatus and full protective equipment. Water or water fog are the preferred extinguishing media. Foam, alcoholresistant foam, carbon dioxide or dry chemicals may also be used. Soak thoroughly with water to cool and prevent re-ignition. 47

46 CALIBRE Polycarbonate Resins Handling Considerations Disposal DO NOT DUMP INTO ANY SEWERS, ON THE GROUND, OR INTO ANY BODY OF WATER. For unused or uncontaminated material, the preferred options include sending to a licensed recycler, reclaimer, incinerator or other thermal destruction device. For used or contaminated material, the disposal options remain the same, although additional evaluation is required (see, for example, 4 CFR, Part 26, Identification and Listing of Hazardous Waste ). All disposal methods must be in compliance with Federal, State/Provincial and local laws and regulations. As a service to its customers, Dow can provide lists of companies which recycle, reprocess or manage chemicals or plastics, and companies that manage used drums. Telephone the Dow Customer Information Center at DOW (4369) for further details. In Mexico, call Environment Generally speaking, in the environment lost pellets are not a problem except under unusual circumstances when they enter the marine environment. They are inert and benign in terms of their physical environmental impact, but if ingested by waterfowl or aquatic life, they may mechanically cause adverse effects. Spills should be minimized and they should be cleaned up when they happen. Plastics should not be discarded into the ocean or any other body of water. Product Stewardship The Dow Chemical Company has a fundamental concern for all who make, distribute and use its products, and for the environment in which we live. This concern is the basis of our Product Stewardship philosophy by which we assess the health and environmental information on our products and then take appropriate steps to protect employee and public health and the environment. Our Product Stewardship program rests with every individual involved with Dow products from initial concept and research to manufacture, sale, distribution and disposal of each product. Customer Notice Dow encourages its customers and potential users of Dow products to review their applications for such products from the standpoint of human health and environmental quality. To help ensure that Dow products are not used in ways for which they are not intended or tested, Dow personnel will assist customers in dealing with ecological and safety considerations. Your Dow sales representative can arrange the proper contacts. Dow literature, including Material Safety Data sheets, should be consulted prior to the use of Dow products. These may be obtained from your Dow sales representative, by writing The Dow Chemical Company or by calling DOW (4369). In Mexico, call

47 For additional information, call the most convenient number for your area: Asia/Pacific: Brazil: Europe: Mexico: U.S.A. and Canada: NOTICE: No freedom from any patent owned by Seller or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer's use and for ensuring that Customer's workplace and disposal practices are in compliance with applicable laws and other governmental enactments. Seller assumes no obligation or liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED. Dow will not knowingly sell or sample any products into any commercial or developmental application that is intended for: a) Long-term contact with internal body fluids or internal body tissues (long-term is a use which exceeds 72 continuous hours [except 3 days for PELLETHANE* thermoplastic polyurethane elastomers]); b) Use in cardiac prosthetic devices regardless of the length of time involved (cardiac prosthetic devices include, but are not limited to: pacemaker leads and devices, artificial hearts, heart valves, intra-aortic balloons and control systems, and ventricular bypass assisted devices); c) Use as a critical component in medical devices that support or sustain human life; or d) Use specifically by pregnant women or in applications designed specifically to promote or interfere with human reproduction. In addition, for Dow Engineering Plastics products, new business opportunities require a business assessment prior to sale or sampling of Dow products. Authorized distributors and resellers will adhere to the Engineering Plastics Business medical policy. The Engineering Plastics business does not endorse or claim suitability of its products for specific medical applications. It is the responsibility of the medical device or pharmaceutical manufacturer to determine that the Dow product is safe, lawful, and technically suitable for the intended use. DOW MAKES NO WARRANTIES, EXPRESS OR IMPLIED, CONCERNING THE SUITABILITY OF ANY DOW PRODUCT FOR USE IN MEDICAL APPLICATIONS. This policy applies to all Engineering Plastics products and technologies including the following: AMPLIFY* thermoplastic alloys, CALIBRE* polycarbonate resins, EMERGE* advanced resins, FULCRUM* thermoplastic composite technology, INSPiRE* performance polymers, ISOPLAST* engineering thermoplastic polyurethane resins, MAGNUM* acrylonitrile butadiene styrene resins, PELLETHANE* thermoplastic polyurethane elastomers, PREVAIL* thermoplastic resins, PULSE* engineering resins, QUESTRA* crystalline polymers, TYRIL* styrene acrylonitrile resins, and VYDYNE** nylon resins. If products are described as experimental or developmental : ) product specifications may not be fully determined; 2) analysis of hazards and caution in handling and use are required; and 3) there is greater potential for Dow to change specifications and/or discontinue production. Published July 2 The Dow Chemical Company, 24 Dow Center, Midland, MI 48674, U.S.A. Dow Chemical Canada Inc., 86 Modeland Rd., P.O. Box 2, Sarnia, Ontario, N7T 7K7, Canada Dow Quimica Mexicana S.A. de C.V., Torre Optima Mezzanine, Av. Paseo de Las Palmas No., Col. Lomas de Chapultepec, Mexico D.F., Mexico Dow Europe S.A., Bachtobelstr. 3, CH-88 Horgen, Switzerland Dow Quimica S.A., Rua Alexandre Dumas, 67, P.O. Box 937, Sao Paulo, Brazil Dow Chemical Pacific Ltd., 47/F, Sun Hung Kai Centre, 3 Harbour Rd., Wanchai, Hong Kong Printed in U.S.A. *Trademark of The Dow Chemical Company. **Registered trademark of Solutia Inc. used by The Dow Chemical Company under license. Dow Plastics, a business group of The Dow Chemical Company and its subsidiaries. Form No X SMG SMG 9788 / McKay XXXXX