shin-etsu lims guide

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Page 1: Shin-Etsu LIMS Guide
Page 2: Shin-Etsu LIMS Guide

INJECTION MOLDING MACHINEAccurate extruded amounts •

Stable shot •

PUMPS • Metering with precision

TO INCREASE PROCESSING EFFICIENCY, TO SAVE ENERGY AND PRODUCTION COSTS, AND TO INCREASE PRODUCT YIELD

LIMS (Liquid Injection Molding System) is a newly designed system, which includes a series of highly functional liquid silicone rubbers and an injection molding machine to precisely inject those fluids. From the set-up of raw materials to blending and molding, the entire process is automated to secure high quality products. Because the raw materials are liquid silicone rubbers, which exhibit excellent properties, they meet a wide range of requirements in the electrical, electronic, automotive and food industries.LIMS saves energy and increases productivity.

LIQUID SILICONE RUBBERSHigh speed curing •

Long pot life •Low viscosity •

Good release properties •High tear strength •

MOLDS • Cold-runner • Flashless • Runnerless

1

Page 3: Shin-Etsu LIMS Guide

AUTOMATING INJECTION MOLDING PROCESS

Good molding characteristics. Excellent release properties after curing. The entire Process can be automated.

NO ENVIRONMENTAL POLLUTION

The curing reaction produces no by-products. If flashless and runnerless molds are used, the treatment of cured wastematerials are eliminated.

EXCELLENT PROPERTIES

Liquid silicone rubbers are highly functional rubbers with heat resistance, electrical insulation, high strength, flame resistance and electric conductivity, and can produce not only transparent goods but also a wide variety of colored products.

SAVING PROCESSING TIME

The curing of liquid silicone rubbers is an addition reaction. The curing speed is rapid, saving significant processing time.

INCREASING PRODUCT YIELD

Because the raw materials are liquid silicone rubbers, which can be injected at low pressure, they are suitable for molding precision parts. The components of A and B can be accurately blended at an accurate ratio, to secure high quality products.

2

Page 4: Shin-Etsu LIMS Guide

KE2000 SeriesThese products are highly transparent, high-strength and fastcuring types of silicones, available in a range of hardnesses from 20˚ to 60˚. Because of molding with flashless and runnerless molds, automation with short cycle is possible.

KE1950 SeriesThese products are transparent and high-strength silicones, available in the range of hardnesses from 10˚ to 70˚.

KE2000-20 (A•B) KE2000-30 (A•B) KE2000-35 (A•B) KE2000-40 (A•B) KE2000-50 (A•B) KE2000-60 (A•B)

Translucent Translucent Translucent Translucent Translucent Translucent

Translucent Translucent Translucent Translucent Translucent Translucent

180 250 500 500 1,000 600

180 250 500 500 1,000 600

Transparent Transparent Transparent Transparent Transparent Transparent

1.08 1.10 1.12 1.12 1.13 1.14

23 32 36 42 52 60

8.5 8.9 9.5 9.2 9.8 9.6

750 670 650 600 550 460

8.0 25 30 30 35 35

5 5 5 6 6 8

2.1 2.0 2.2 2.1 2.0 1.9

10 10 10 10 10 10

Fast curing, highly transparent, high strength

Pa•s

KE1950-10 (A•B) KE1950-20 (A•B) KE1950-30 (A•B) KE1950-35 (A•B) KE1950-40 (A•B) KE1950-50 (A•B)

Translucent Translucent Translucent Translucent Translucent Translucent

Translucent Translucent Translucent Translucent Translucent Translucent

60 150 250 500 480 680

60 150 250 500 480 680

Transparent Transparent Transparent Transparent Transparent Transparent

1.08 1.10 1.10 1.12 1.12 1.13

13 20 32 36 42 52

3.9 6.4 8.8 9.8 9.8 9.3

700 900 700 700 650 550

10 25 25 30 35 40

12 15 22 36 20 28

2.3 2.1 2.0 2.2 2.1 2.0

10 10 10 10 10 10

Transparent, high strength

*1 Brookfield-type rotational viscometer *2 5 minutes press-curing at 120˚C(248˚F) 1 hour post-curing at l50˚C(302˚F)

LIMS are liquid silicone rubbers, which exhibit excellent heat resistance, electrical insulation, radiation resistance and corona resistance of conventional silicone rubbers.Shin-Etsu provides a number of LIMS grades for use in a wide range of applications such as general-purpose, high strength, transparent and flame resistant types. We continue to develop new products to meet specific requirements of our customers.

General Properties

Before curing

After curing *

2

Items

products

Liquid A

Liquid B

Liquid A

Liquid B

Appearance

Appearance

Specific gravity at 23˚C (73.4 ˚F)

Hardness, Durometer type A

Tensile strength MPa

Elongation at break %

kN/m

Compression set *3 %

Linear shrinkage %

Volume resistivity TΩ•m

Viscosity*1

Tear strength, crescent type

Before curing

After curing*

2

Items

products

Liquid A

Liquid B

Liquid A

Liquid B

Appearance

Viscosity*1

Tear strength, crescent type

Appearance

Specific gravity at 23˚C(73.4 ˚F)

Hardness, Durometer type A

Tensile strength MPa

Elongation at break %

kN/m

Compression set %

Linear shrinkage %

Volume resistivity TΩ•m

3

Page 5: Shin-Etsu LIMS Guide

KE1990 SeriesThese products are general-purpose silicones, available in hardness of 40˚, 50˚, and 60˚. They are designed primarily for use in keypad applications. KE1990-40 meets the standards of UL 94HB, KE1990-50 and KE1990-60 are equivalents of UL 94HB.

KE1955 (A•B)This product is a flame resistant silicone, it meets the standards of UL V-0.

KE1935 (A•B), KE 1987 (A•B), KE 1988 (A•B)These materials are suitable for making highly transparent products.

KE2010(A•B), KE2011 (A•B), KE1995 (A•B)These products are oil resistant types, KE1995 is qualified under JIS B 2401 4 type C (O-rings).

Highly transparent, high strength

KE1950-60 (A•B) KE1950-70 (A•B)

Translucent Translucent

Translucent Translucent

730 750

740 750

Transparent Transparent

1.14 1.15

60 70

7.8 7.8

380 350

35 40

22 50

1.9 2.1

10 10

KE1990-40 (A•B) KE1990-50 (A•B) KE1990-60 (A•B)

Translucent Translucent Translucent

Translucent Translucent Translucent

90 60 120

90 60 120

Translucent Translucent Translucent

1.12 1.12 1.15

39 50 60

6.5 7.0 7.0

380 300 250

6 7 8

9 10 10

2.0 1.8 1.8

5 5 5

General purposes Flame resistant

KE1955 (A•B)

Black

Black

700

700

Black

1.25

55

8.5

450

30

10

1.8

100

KE1935 (A•B) KE1987 (A•B) KE1988 (A•B)

Transparent Translucent Translucent

Transparent Translucent Translucent

80 700 600

45 700 450

Transparent Transparent Transparent

1.03 1.15 1.15

55 55 62

5.9 8.3 7.8

350 430 250

8.0 35 35

30 50 49

3.2 2.1 2.2

10 100 100

Highly transparent

KE2010 (A•B)*4 KE2011 (A•B) KE1995 (A•B)

Gray Gray Reddish brawn

Gray Gray Reddish brawn

800 1,000 400

800 1,000 400

Gray Gray Reddish brawn

1.23 1.21 1.59

50 50 72

8.5 8.5 5.9

450 450 110

20 25 5.0

10 10 9

1.8 1.8 1.9

50 50 50

Oil resistant

*3 5 minutes press-curing at 120˚C(248˚F) 4 hours post-curing at 200˚C(392˚F) *4 Oil bleed type *5 According to JIS 6249 testing method (not specified values)

PIGMENTS FOR COLORING LIMS SILICONE RUBBERS

The following pigments are for coloring LIMS materials, Oil-bleed pigments are also available.

*Please contact us for other colors of pigments.

PIGMENTS FOR OIL BLEEDProducts Color

LIMS Color-01 Black

LIMS Color-03 Reddish brown

LIMS Color-06 Brown Grayish-green

PIGMENTSProducts Color

LIMS Color-02 Black

LIMS Color-04 Orange

LIMS Color-05

Before curing

After curing*

2

Items

products

Liquid A

Liquid B

Liquid A

Liquid B

Appearance

Viscosity*1

Tear strength,crescent type

Before curing

After curing*

2

Items

products

Liquid A

Liquid B

Liquid A

Liquid B

Appearance

Viscosity*1

Tear strength,crescent type

Pa•s

Pa•s

Appearance

Specific gravity at 23˚C(73.4 ˚F)

Hardness, Durometer type A

Tensile strength MPa

Elongation at break %

kN/m

Compression set %

Linear shrinkage %

Volume resistivity TΩ•m

Appearance

Specific gravity at 23˚C(73.4 ˚F)

Hardness, Durometer type A

Tensile strength MPa

Elongation at break %

kN/m

Compression set %

Linear shrinkage %

Volume resistivity TΩ•m

4

Page 6: Shin-Etsu LIMS Guide

Pt

CH3

OSi-CH=CH2+H-Si-CH3

CH3 O CH3

CH3- Si-H+CH2=CH-SiO

CH3 O CH3

OSi-CH=CH2+H-Si-CH3

CH3

CH3

OSiCH2CH2Si- CH3

CH3 O CH3

CH3- SiCH2CH2SiO

O CH3CH3

OSi- CH2CH2- Si- CH3

CH3

5

1. Curing TemperatureAlthough the optimum curing temperature varies with the thickness and shape of the product, standard temperatures range from 130˚C (266˚F) to 200˚C (392˚F), but curing is possible at temperatures as low as 90˚C (194˚F) and as high as 210˚C (410˚F).

2. Injection PressureOptimum results are obtained at a curing temperature of 130˚C (266˚F) - 200˚C (392˚F) , at pressure ranging from 40 kg/cm2 to 120 kg/cm2.

3. Curing TimeProducts can be molded in a very short cycle, no more than 10 seconds per millimeter thickness at 150˚C (302˚F).

4. Apparent ViscosityApparent viscosity varies with shear rate, the relationship is indicated by a straight line on a logarithmic graph (please refer to Figure: Viscosity on page 6).

5. Linear ShrinkageLinear shrinkage ranges from 2% to 3% at temperatures between 100˚C (212˚F) to 150˚C (302˚F).(please refer to the table of General Properties on page 3-4).

6. Pot LifePot life after mixing the components of A and B varies with temperatures. Typically, the viscosity remains constant for72 hours at room temperature (25˚C (77˚F)). To extend the pot life, a chiller (a cooling device) set in the mixing section is recommended.

Curing MechanismCuring of liquid silicone rubber occurs by an addition reaction as illustrated below. The cure rate is accelerated when the materials are heated.

Page 7: Shin-Etsu LIMS Guide

6

10000

days Shear rate (1/sec)

8000

6000

4000

2000

00 2 4 6

Pot Life vs. Viscosity

8 10

25˚C(77˚F)

5˚C(41˚F)

1000

100

10

Cu

rin

g t

ime

(sec

) (T

10)

1/T (X10-3 K-1)

12.0 2.2 2.4 2.6

Molding Temperature vs. Curing Time

2.8

150˚C(302˚F)

6.0

5.0

4.0

3.0

2.0

1.0

0

Torq

ue

(MP

a)

Time : min.

00 0.5 1.0 1.5

Curing Characteristics

2.0 2.5

103

102

101

Vis

cosi

ty(P

a•s)

Vis

cosi

ty(P

a•s)

1102 103

Viscosity

104

•Flow Tester : l .0 X 10 mm L

Common siliconeKE951-U 25˚C (77˚F)

25˚C (77˚F)

150˚C(302˚F)

180˚C(326˚F)

120˚C(248˚F)

VISCOSITY AND CURING CHARACTERISTICS OF KE2000 - 40 (A•B)

KE2000-40

KE 1950-40

Page 8: Shin-Etsu LIMS Guide

Mixer

The components are mixed thoroughly by a dynamic or static mixer, and injected by pressure directly into the mold.

Injector

Pressure and injection velocity are set (LIMS silicones can be molded at a very low injection pressure).

Material feeder pump

Pails (or drums) of components A and B are set and feed into the pump.

Shut-off nozzle

A shut-off mechanism prevents material leaking from the nozzles.

Mold closing

The closing and opening of the mold die are operated sequentially with the feeder pump, the metering pump and the injector.

Metering discharge pump

Components A and B are metered accurately at a 1:1 ratio by a pressure pump and discharged.

Mold

A P

P(Pigments):option

B

7

Molding machines corresponding to viscosity ranges of liquid silicone rubbers (50 - 2,000 poise) at room temperature, should be used.Basically, the injection molding system includes a

Basic Design of LIMS Molding Machine

quantitative delivery pump and a dynamic or static mixer. There are compact injection molding machines especially designed for high precision LIMS (Please contact Shin-Etsu for details).

Page 9: Shin-Etsu LIMS Guide

Extend curing time and increase temperature

Increase pressure

Vent the pails completely and adjust injection velocity

Adjust heating unit

Extend curing time

Vent the pails completely

Prevent air entrapment during injection

Decrease temperature of metal mold, control temperature distribution of metal mold

Adjust injection velocity, and check the mixer

Adjust volume mixer and injection velocity

Increase the pressure and decrease the temperature

Decrease injection time

Provide air vent

Balance gate

Extend curing time, increase temperature of metal mold

Use polished metal mold with hard chromium plating and apply proper quantity of release agent.

Extend curing time

Repair metal mold

Check the heating method

Check nozzles

Eliminate curing inhibition materials

Check the mixing system

Incomplete curing

Insufficient molding pressure

Entrapped air

Uneven heating

Incomplete curing

Insufficient air vent

Entrapped air

Excess temperature of metal mold

Incomplete mixing

Fluctuation in mixing ratio or incomplete mixing

Improper molding pressure

Excess injection time

Poor air vent at fused part

Defective gate port

Incomplete curing

Rough surface of metal mold

Improper curing conditions

Defective surface condition of metal mold

Uneven distribution of surface temperature

Wear and incision on nozzles

Curing inhibition

Improper mixing ratio

Defects Causes Countermeasures

Blisters

Voids

Rough surfaces

Uneven color

Weld marks

Poor luster

Poor mold releasing

Leakage from nozzles

Incomplete curing

8

ADVICE FOR SYSTEM DESIGN

MOLDING DEFECTS, CAUSES AND COUNTER-MEASURES

• Proper selection of seals for injection machinery is essential to the ultimate performance of the system. For example, nitride steel or ceramics should be used for sliding or rotating contacts where there is a potential for metal-to-metal contact. To avoid seepage of materials, 1- 3 ply Teflon packing are recommended.

• Because of the liquid nature of the raw materials, molds voids should be tightly sealed to prevent leakage.

• Abrasion resistant materials should be used for mechanical parts (mixer and mold die) to avoid wear caused by the filler in liquid silicone rubbers.

• It is important that there are no dead spaces where silicones can accumulate in the shut-off nozzles, clamps and molds after the mixing process occurs.

• Liquid silicone rubbers are compressed liquids. Flowcontrol of each component is necessary when molding.

• The mold should be equipped with at least one vent for quick air release.

Please contact us for the other details.

Page 10: Shin-Etsu LIMS Guide

General properties of Primer No. 4

Product Primer No. 4

Appearance light yellow, transparent

Viscosity 0.2 - 1.0mm2/s

Specific gravity 0.77 - 0.78

Non-volatile matter 6 - 8%

Solvent Ligroin

Pot life 24 hours

Drying Air drying for l5 minutes

9

Primer No. 4Primer No. 4 is a general use primer, because of its low viscosity, it is easy to handle and has excellent drying property.

• How to apply • Apply the primer to the metal either by brushing, dipping

or spraying. • Wait about 15 minutes at room temperature after the

primer is applied. • Pot life is 24 hours after the primer is applied.

FOR GENERAL PURPOSES

The General Properties of Primer X-33-156-20

Product Primer X-33-156-20

Appearance light yellow

Viscosity 0.2 - 1.0mm2/s

Specific gravity 0.70 - 0.72

Non-volatile matter 3 - 5%

Pot life 24 hours

Primer X-33-156-20Premier X-33-156-20 is especially good for bonding to plastics, and it can either be air dried or oven baked.

• How to apply • It can be applied by either dipping, brushing or spraying. • Primed inserts may be used after 30 minutes of air drying

at room temperature. Adhesion is improved, if the inserts are baked in an oven at 80˚C(176˚F) - 120˚C(248˚F) for 10 - 20 minutes after 30 minutes of air drying.

• Pot life is 24 hours after the primer is applied. • Containers should be kept in a cool and dark place. • The solvent used as a diluent should be handled with

caution.

FOR BONDING TO PLASTICS

Page 11: Shin-Etsu LIMS Guide

KE2000-20(A•B)

KE2000-30(A•B)

KE2000-35(A•B)

KE2000-40(A•B)

KE2000-50(A•B)

KE2000-60(A•B)

KE1950-10(A•B)

KE1950-20(A•B)

KE1950-30(A•B)

KE1950-35(A•B)

KE1950-40(A•B)

KE1950-50(A•B)

KE1950-60(A•B)

KE1950-70(A•B)

KE1990-40(A•B)

KE1990-50(A•B)

KE1990-60(A•B)

KE1955(A•B)

KE1935(A•B)

KE1987(A•B)

KE1988(A•B)

KE2010(A•B)

KE2011(A•B)

KE1995(A•B)

Packing

Products 18-liter can

18 kg 20 kg 180 kg 200 kg

180-liter drum

10

1. Materials such as amines, sulfur, organic phosphorus compounds or organic tin compounds may cause curing inhibition of liquid silicone rubber. A preliminary curing test is recommended.

• Materials that may cause curing inhibition. • Chloroprene and other synthetic rubbers • Sulfur compounds • Plasticized polyvinyl chloride resins • Amine cured epoxy resins • PVC insulating tapes • Resin containing soldering fluxes

2. Liquid silicone rubbers should be stored in a cool and dark place, away from rain or humidity.

Quality

1. When using LIMS materials in medical appliances or food equipment, users should confirm that they conform to appropriate regulations.

2. If LIMS materials contact the skin, wipe them off immediately and clean the area with soap.

3. If the materials get into eyes, wash them immediately with a large amount of water and see an eye doctor if necessary.

4. Contact of component B with alkali substance may cause the evolution of flammable hydrogen gas. Precautions should be taken to prevent this.

5. Please contact our sales division for material safety data sheets (MSDS).

Safety Guide

PACKING

Page 12: Shin-Etsu LIMS Guide

C Shin-Etsu 2000.2/2001.9 1 2.B.P. Printed in Japan.

The data and information presented in this catalog may not be relied upon to represent standard values. Shin-Etsu reserves the right to change such data and information, in whole or in part, in this catalog, including product performance standards and specifications without notice.

Users are solely responsible for making preliminary tests to determine the suitability of products for their intended use. Statements concerning possible or suggested uses made herein may not be relied upon, or be construed, as a guaranty of no patent infringement.

The silicone products described herein have been designed, manufactured and developed solely for general industrial use only; such silicone products are not designed for, intended for use as, or suitable for, medical, surgical or other particular purposes. Users have the sole responsibility and obligation to determine the suitability of the silicone products described herein for any application, to make preliminary tests, and to confirm the safety of such products for their use.

Users must never use the silicone products described herein for the purpose of implantation into the human body and/or injection into humans.

Users are solely responsible for exporting or importing the silicone products described herein, and complying with all applicable laws, regulations, and rules relating to the use of such products. Shin-Etsu recommends checking each pertinent country’s laws, regulations, and rules in advance, when exporting or importing, and before using, the products.

Please contact Shin-Etsu before reproducing any part of this catalog. Copyright belongs to Shin-Etsu Chemical Co., Ltd.

Silicone Division, Overseas Planning and Administration Department6-1, Ohtemachi 2-chome, Chiyoda-ku, Tokyo, Japan

Phone : +81-(0)3-3246-5171 Fax : +81-(0)3-3246-5363

Shin-Etsu Silicones of America, Inc.1150 Damar Drive, Akron, OH 44305, U.S.A.

Phone : +1-330-630-9860 Fax : +1-330-630-9855

Shincor Silicones, Inc.1030 Evans Avenue, Akron, OH 44305, U.S.A.

Phone : +1-330-630-9460 Fax : +1-330-630-1491

Shin-Etsu Silicones Europe B. V.Bolderweg 32, 1332 AV, Almere, The Netherlands

Phone : +31-(0)36-5493170 Fax : +31-(0)36-5326459

Shin-Etsu Silicone Taiwan Co., Ltd.7F, No.102, Civil Boulevard, Sec.4, Taipei, Taiwan R.O.C.

Phone : +886-(0)2-2751-6999 Fax : +886-(0)2-2751-6769

Shin-Etsu Silicone Korea Co., Ltd.International Insurance Bldg. 904, 120, 5-ka,

Namdaemoon-ro, Chung-ku, Seoul, Korea

Phone : +82-(0)2-775-9691 Fax : +82-(0)2-775-9690

Shin-Etsu Singapore Pte. Ltd.150 UBI Avenue 4, #03-00, Singapore 408825

Phone : +65-6743-7277 Fax : +65-6743-7477

Shin-Etsu Chemical Co., Ltd. Shanghai Liaison Office2211 Shui On Plaza, 333 Huaihai Zhong Road,

Shanghai, China

Phone : +86-(0)21-5306-9966 Fax : +86-(0)21-5382-3970

http://www.silicone.jp/

JAB CEARTIFICATE No.R003

JAB CEARTIFICATE No.RE006