https://www.avient.com/sites/default/files/2022-10/Edgetek Toughened PPA Technical Bulletin.pdf
The filled and unfilled grades are also highly
customizable to achieve a wide range of properties
and solve application challenges.
KEY CHARACTERISTICS
• High-temperature performance
• Excellent impact resistance
• Decreased moisture absorption compared
to PA66
• Heat stabilized for long-term thermal aging
• Enhanced chemical resistance
• Customizable formulations in filled and
unfilled grades
MARKETS & APPLICATIONS
The combined performance characteristics make
Edgetek Toughened PPA ideal for a range of rigid
engine applications.
Leveraging Avient’s material science expertise, Edgetek Toughened PPA formulations can be customized using
various glass loading or impact modifier levels to meet specific application needs.
https://www.avient.com/sites/default/files/2023-05/Hydrocerol Chemical Foaming Agents - Tailgate Trim - Application Snapshot.pdf
AUTOMOTIVE OEM
T A I L G A T E T R I M
• Reduce part weight
• Suitable solution for PP talcum-filled material
• Class A surface finish
• Compatible with core-back injection molding process
• Offered a broad portfolio of solutions
• Provided technical support to help with product
selection and processing parameters
• Reduced part weight by 18%
• Decreased cycle time by 8%
• Enabled good surface appearance for the tailgate
trim
Hydrocerol™ Chemical Foaming Agents
KEY REQUIREMENTS
WHY AVIENT?
https://www.avient.com/sites/default/files/2020-09/lubrione-processing-guide.pdf
Venting
• Place vents at the end of fill and anywhere potential knit/weld lines will occur
Cut vent depths to:
- PPA Compounds: 0.0015"–0.0025" depth and 0.250" width
- PC Compounds: 0.002"–0.004" depth and 0.250" width
- PSU Compounds: 0.003"–0.004" depth and 0.250" width
- PES Compounds: 0.003"–0.004" depth and 0.250" width
- PPS Compounds: 0.002"–0.003" depth and 0.250" width
- Acetal Compounds: 0.0015" minimum depth and 0.250" width
- PEEK Compounds: 0.002"–0.004" depth and 0.250" width
- Nylon Compounds: 0.002" minimum depth and 0.250" width
• Increase vent depth to 0.060" (1.5mm) at 0.250" (4.0mm) away from the cavity
and vent to atmosphere.
PROBLEM CAUSE SOLUTION
Incomplete Fill Melt and/or mold
temperature too cold
Mold design
Shot Size
• Increase nozzle and barrel temperatures
• Increase mold temperature
• Increase injection speed
• Increase pack and hold pressure
• Increase nozzle tip diameter
• Check thermocouples and heater bands
• Enlarge or widen vents and increase number of vents
• Check that vents are unplugged
• Check that gates are unplugged
• Enlarge gates and/or runners
• Perform short shots to determine fill pattern and verify
proper vent location
• Increase wall thickness to move gas trap to parting line
• Increase shot size
• Increase cushion
Brittleness Melt temperature too low
Degraded/Overheated material
Gate location and/or size
• Increase melt temperature
• Increase injection speed
• Measure melt temperature with pyrometer
• Decrease melt temperature
• Decrease back pressure
• Use smaller barrel/excessive residence time
• Relocate gate to nonstress area
• Increase gate size to allow higher flow speed and
lower molded-in stress
Fibers on Surface
(Splay)
Melt temperature too low
Insufficient packing
• Increase melt temperature
• Increase mold temperature
• Increase injection speed
• Increase pack and hold pressure, and time
• Increase shot size
• Increase gate size
Sink Marks Part geometry too thick
Melt temperature too hot
Insufficient material volume
• Reduce wall thickness
• Reduce rib thickness
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Increase shot size
• Increase injection rate
• Increase packing pressure
• Increase gate size
Flash Injection pressure too high
Excess material volume
Melt and/or mold
temperature too hot
• Decrease injection pressure
• Increase clamp pressure
• Decrease injection speed
• Increase transfer position
• Decrease pack pressure
• Decrease shot size
• Decrease injection speed
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Decrease screw speed
TROUBLESHOOTING RECOMMENDATIONS
PROBLEM CAUSE SOLUTION
Excessive Shrink Too much orientation • Increase packing time and pressure
• Increase hold pressure
• Decrease melt temperature
• Decrease mold temperature
• Decrease injection speed
• Decrease screw rpm
• Increase venting
• Increase cooling time
Not Enough Shrink Too little orientation • Decrease packing pressure and time
• Decrease hold pressure
• Increase melt temperature
• Increase mold temperature
• Increase injection speed
• Increase screw rpm
• Decrease cooling time
Burning Melt and/or mold
temperature too hot
Mold design
Moisture
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Decrease injection speed
• Clean, widen and increase number of vents
• Increase gate size or number of gates
• Verify material is dried at proper conditions
Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature
• Decrease back pressure
• Increase screw decompression
• Verify material has been dried at proper conditions
Weld Lines Melt front temperatures
too low
Mold design
• Increase pack and hold pressure
• Increase melt temperature
• Increase vent width and locations
• Increase injection speed
• Increase mold temperature
• Decrease injection speed
• Increase gate size
• Perform short shots to determine fill pattern and verify
proper vent location
• Add vents and/or false ejector pin
• Move gate location
Warp Excessive orientation
Mold design
• Increase cooling time
• Increase melt temperature
• Decrease injection pressure and injection speed
• Increase number of gates
Sticking in Mold Cavities are overpacked
Mold design
Part is too hot
• Decrease injection speed and pressure
• Decrease pack and hold pressure
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Increase cooling time
• Increase draft angle
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Increase cooling time
TROUBLESHOOTING RECOMMENDATIONS
Note: These are general processing conditions.
https://www.avient.com/sites/default/files/2020-11/gls-acqua-plose-case-study.pdf
In 2014,
it was spun off from Closure Systems International (CSI),
and currently produces over three billion aluminum
closures annually in 28 and 30 millimeter diameters
suitable for any type of still, carbonated or alcoholic
beverage packaged in glass, PET or aluminum bottles.
Sealing of reusable
glass bottles with rim imperfections presents an even
greater challenge compared to sealing of one-way,
disposable bottles.
Avient offers GLS TPE cap liner formulations that are
suitable for aqueous, acidic and low alcohol beverages
processed under ambient, pasteurized
or hot fill conditions.
https://www.avient.com/news/bettcher-industries-replaces-aluminum-motor-housing-avient-complēt-long-fiber-composite
Avient identified its Complēt™ long glass fiber reinforced nylon composite as the right material to deliver the required strength and enhanced performance.
Avient conducted virtual prototyping, such as mold filling and finite element analysis (FEA), on a redesigned yoke, while Bettcher conducted testing on a physical prototype to simulate a half million use cycles.
Examples include:
• Barrier technologies that preserve the shelf-life and quality of food, beverages, medicine and other perishable goods through high-performance materials that require less plastic
• Light-weighting solutions that replace heavier traditional materials like metal, glass and wood, which can improve fuel efficiency in all modes of transportation
• Breakthrough technologies that minimize wastewater and improve the recyclability of materials and packaging across a spectrum of end uses
https://www.avient.com/news/avient-adds-recycled-and-bio-based-polyolefin-formulations-its-sustainability-portfolio-k-2022
They can be filled and reinforced or blended with glass, minerals, impact modifiers, colorants, and stabilizer systems to satisfy the required performance characteristics, including flame retardant performance.
Light-weighting solutions that replace heavier traditional materials like metal, glass, and wood, which can improve fuel efficiency in all modes of transportation and reduce carbon footprint
https://www.avient.com/sites/default/files/2020-09/bettcher-case-study-1.pdf
METAL REPLACEMENT
COMBINES METAL’S
STRENGTH WITH
PLASTIC’S LIGHT WEIGHT
CASE STUDY: COMPLĒT™ LONG GLASS FIBER REINFORCED COMPOSITE
Ch
all
en
ge
A
cc
ep
te
d.
With lightweighting benefits and design freedom, this
high-end composite was shown in mold filling and
FEA analysis to maintain the reliability and strength of
metal.
Using the new Complēt long glass fiber nylon
formulation, the redesigned yoke underwent testing
at Bettcher to simulate 500,000 run cycles.
https://www.avient.com/sites/default/files/2023-01/Hydrocerol Chemical Foaming Agents for Injection Molding Technical Bulletin.pdf
INJECTION RATE
The mold cavity needs to be filled at high speed to
maintain a high pressure until the end-of-fill and
ensure that the dispersed gas bubbles create the
necessary expansion after the pressure drop at the
end of the injection process.
The sliding
back of the mold cavity at the end of fill allows a
greater pressure drop and herewith more expansion.
Once the cavity is filled, the mold opens, or
one of the sides has a slide, to allow the expansion of
the gas-loaded compound.
https://www.avient.com/sites/default/files/2023-11/Capture Oxygen Scavenger Product Bulletin.pdf
KEY CHARACTERISTICS
• Extends product shelf life and reduces
waste
• Maintains clarity and aesthetics of the bottle
while keeping contents fresh
• Located in the closure, eliminating the need
to add a scavenger to the container wall
• Allows unlimited design freedom, including
lightweighting
• Has achieved APR Critical Guidance Recognition
• Allows up to 100% rPET usage
• Does not negatively impact the PET or polyolefin
recycle streams
PRODUCT BULLETIN
PROCESSING PARTICULARS
Capture is designed to work with 1-piece
HDPE and PP plug seal closures.
The technology can be used
with PET or rPET bottles and is suitable for
both hot-fill and aseptic filling operations.
https://www.avient.com/products/engineered-polymer-formulations/general-engineered-formulations/maxxam-polyolefin-formulations
Maxxam™ formulations are based on polypropylene and polyethylene resins and can be filled and reinforced to satisfy the required performance characteristic.
They can be blended with glass, minerals, impact modifiers, colorants and stabilizer systems, providing customized solutions to meet specific application needs.