INJECTION MOLDING MACHINE
Accurate 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 RUBBERS
High speed curing •
Long pot life •
Low viscosity •
Good release properties •
High tear strength •
MOLDS
• Cold-runner
• Flashless
• Runnerless
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 waste materials 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.
KE2000 Series
These products are highly transparent, high-strength and fast curing 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 Series
These 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•mKE1990 Series
These 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 BLEED
Products Color LIMS Color-01 Black LIMS Color-03 Reddish brown
LIMS Color-06 Brown Grayish-green PIGMENTS Products 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
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- CH
3 CH3 CH3 OSiCH2CH2Si- CH3 CH3 O CH3 CH3- SiCH2CH2SiO O CH3 CH3 OSi- CH2CH2- Si- CH3 CH3 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 Pressure
Optimum 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 Time
Products can be molded in a very short cycle, no more than 10 seconds per millimeter thickness at 150˚C (302˚F). 4. Apparent Viscosity
Apparent 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 Shrinkage
Linear 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 Life
Pot life after mixing the components of A and B varies with temperatures. Typically, the viscosity remains constant for 72 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 Mechanism
Curing of liquid silicone rubber occurs by an addition reaction as illustrated below. The cure rate is accelerated when the materials are heated.
10000
days Shear rate (1/sec)
8000 6000 4000 2000 0 0 2 4 6
Pot Life vs. Viscosity
8 10 25˚ C ( 7 7 ˚ F ) 5˚ C ( 4 1 ˚ F ) 1000 100 10
Curing time (sec) (T
10
)
1/T (X10-3 K-1)
1
2.0 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 T o rque (MP a) Time : min. 0 0 0.5 1.0 1.5
Curing Characteristics
2.0 2.5 103 102 101 Viscosity(P a•s) Viscosity(P a•s) 1 102 103Viscosity
104 • F l ow Te s t e r : l . 0 X 1 0 m m L Common silicone KE951-U 25˚C (77˚ F ) 2 5 ˚C (7 7 ˚ F ) 150˚ C ( 3 0 2 ˚ F ) 1 8 0 ˚ C ( 3 2 6 ˚ F ) 1 2 0 ˚ C ( 2 4 8 ˚ F )VISCOSITY AND CURING CHARACTERISTICS OF KE2000 - 40 (A•B)
KE2000-40
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
Molding machines corresponding to viscosity ranges of liquidsilicone 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).
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
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. Flow control of each component is necessary when molding.•
The mold should be equipped with at least one vent for quick air release.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
Primer No. 4
Primer 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-33-156-20
Premier 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.
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
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
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 Department
6-1, 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 Office
2211 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