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Radio transparency and high dielectric properties makes long glass fiber reinforced thermoplastic an ideal material for consumer electronic items that utilize wireless transmission technologies.

The obligation to “indemnify and hold harmless” included in this section shall mean the obligation of Buyer to cover any damage, costs and expenses suffered or incurred by Seller and pay the relevant amounts to Seller as well as to release Seller from any liability towards third parties (Article 392 of the Polish Civil Code). No statement of agreement, oral or written, made before or at the formation of the contract shall vary or modify the written terms hereof, and neither party shall claim any amendment, modification or release from any provision hereof unless such change occurs in a writing signed by the other party and specifically identifying it as an amendment to the contract. No modification or addition to the contract shall occur by the acknowledgment or acceptance by Seller of a purchase order, acknowledgment, release or other form submitted by Buyer containing additional or different terms or conditions. 19.

All interior and exterior rounds need to be concentric.1 DRAFT The draft on a part is a taper on the walls perpendicular to the parting line to allow the part to release from the mold . DEFECTS Design Guide 29 SOURCES Mold Machine Material Process Mold too hot Wrong screw configuration Contamination Wet material Injection speed too fast Melt temperature too low Residence time too low Back pressure too low RECOMMENDED ADJUSTMENTS Clean mold surface Stop using mold spray Check mold for condensation Make sure material is thoroughly mixed Dry material Check for contamination Reduce injection speed Increase melt temperature Increase mold temperature Increase injection speed Delamination Root cause: Either contamination or extremely high degree of orientation. 30 Gravi-Tech SOURCES Mold Machine Material Process Mold temperature too high Venting plugged Cycle too short Check ring slippage New lot of material Under-packing RECOMMENDED ADJUSTMENTS Increase gate size Check for proper venting Increase pack pressure Increase hold time Increase melt temperature Reduce mold temperature Reduce transfer position Increase cooling time Dimension—Small • A DOE should be run to conclude which processing parameters have the greatest influence on part size DEFECTS Design Guide 31 SOURCES Mold Machine Material Process Mold temperature too cold Hot runner too hot Running out of material New lot of material Contamination Over-packing RECOMMENDED ADJUSTMENTS Increase gate size Check for proper venting Reduce hold pressure Reduce melt temperature Reduce hold time Increase mold temperature Increase transfer position Dimension—Large • A DOE should be run to conclude which processing parameters have the greatest influence on part size 32 Gravi-Tech SOURCES Mold Machine Material Process Tooling damage Rolled parting lines Bent cores Plating worn off Mold too cold Broken ejector pin Running out of material Barrel malfunction Contamination Wet material Melt temperature too high Over- or under-packed Cooling time too high or low Injection speed too high Escessive back pressure RECOMMENDED ADJUSTMENTS Reduce ejection velocity Check for mold damage Use mold release Reduce mold finish Check for heaters overriding Dry material Increase/decrease hold pressure Reduce hold time Increase/decrease mold temperature Reduce injection speed Reduce back pressure Distortion/Deformation Root cause: Various causes—parts too hot to eject/packing/poor ejection design/tooling damage/ high polish . End of Fill Part Length Dynamic Pressure Hydrostatic Pressure P re s s u re Gate End Part FIGURE 61 - Deflection Equations H F WLMax Deflection: 0.002" (0.05mm) 1 = W • H3 12 _______ bending = F • L3 48 • E • I _______ 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline FIGURE 60 - Pressure vs Part Length FIGURE 61 - Deflection equations FIGURE 62 - For Plate Shaped Parts FIGURE 63 - For Cylindrical Shaped Parts Design Guide 49 • M Moldings = Combined mass of molded parts • C p = Specific Heat of the material Step 3 – Heat Removal Rate • N lines = The total number of independent cooling lines there are in the mold • t c = The cooling time required by the part (Determined in step 1) Step 4 – Coolant Volumetric Flow Rate • ΔT Max,Coolant = Change in coolant Temperature During Molding (1°C) • ρ Coolant = Density of coolant • CP = Specific heat of coolant Step 5 – Determine Cooling Line Diameter • ρ Coolant = Density of coolant • V Coolant = Volumetric flow rate of coolant • μ Coolant = Viscosity of coolant • ΔP line = Max pressure drop per line (Usually equals half of the pump capacity) • L Line = Length of the cooling lines COOLING LINE SPACING 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline 4 π tc = h2 1n π2 • a • Tmelt – Tcoolant Teject – Tcoolant tc = D2 1.61n 23.1 • a Tmelt – Tcoolant Teject – Tcoolant a = k p * Cp Qmoldings = mmoldings • Cp • Tme • Cplt – Teject cooling nlines moldings tccooling Vcoolant line nmax, coolant • Pcoolant • Cp, coolant Dmax = 4 • Pcoolant • Vcoolant π • µcoolant • 4000 Dmin = Pcoolant • Lline • V2coolant5 10π • ∆Pline 2D < H line < 5D H line < W line < 2H line FIGURE 70 - Cooling Line Spacing FIGURE 64 - Heat Transfer Equation FIGURE 65 - Total Cooling for Mold FIGURE 66 - Cooling Required by Each Line FIGURE 68 - Max Diameter Equation FIGURE 69 - Min Diameter Equation FIGURE 67 - Volumetric Flow Rate Equation 50 Gravi-Tech ADHESIVE ADVANTAGES DISADVANTAGES Cyanoacrylate Rapid, one-part process Various viscosities Can be paired with primers for polyolefins Poor strength Low stress crack resistance Low chemical resistance Epoxy High strength Compatible with various substrates Tough Requires mixing Long cure time Limited pot life Exothermic Hot Melt Solvent-free High adhesion Different chemistries for different substrates High temp dispensing Poor high temp performance Poor metal adhesion Light Curing Acrylic Quick curing One component Good environmental resistance Oxygen sensitive Light source required Limited curing configurations Polyurethane High cohesive strength Impact and abrasion resistance Poor high heat performance Requires mixing Silicone Room temp curing Good adhesion Flexible Performs well in high temps Low cohesive strength Limited curing depth Solvent sensitive No-Mix Acrylic Good peel strength Fast cure Adhesion to variety of substrates Strong odor Exothermic Limited cure depth Design Guide 51 Bibliography 1 .

No statement of agreement, oral or written, made before or at the formation of the contract shall vary or modify the written terms hereof, and neither party shall claim any amendment, modification or release from any provision hereof unless such change occurs in a writing signed by the other party and specifically identifying it as an amendment to the contract. No modification or addition to the contract shall occur by the acknowledgment or acceptance by Seller of a purchase order, acknowledgment, release or other form submitted by Buyer containing additional or different terms or conditions. 21.

No statement of agreement, oral or written, made before or at the formation of the contract shall vary or modify the written terms hereof, and neither party shall claim any amendment, modification or release from any provision hereof unless such change occurs in a writing signed by the other party and specifically identifying it as an amendment to the contract. No modification or addition to the contract shall occur by the acknowledgment or acceptance by Seller of a purchase order, acknowledgment, release or other form submitted by Buyer containing additional or different terms or conditions. 20.

No statement of agreement, oral or written, made before or at the formation of the contract shall vary or modify the written terms hereof, and neither party shall claim any amendment, modification or release from any provision hereof unless such change occurs in a writing signed by the other party and specifically identifying it as an amendment to the contract. No modification or addition to the contract shall occur by the acknowledgment or acceptance by Seller of a purchase order, acknowledgment, release or other form submitted by Buyer containing additional or different terms or conditions. 20.

No statement of agreement, oral or written, made before or at the formation of the contract shall vary or modify the written terms hereof, and neither party shall claim any amendment, modification or release from any provision hereof unless such change occurs in a writing signed by the other party and specifically identifying it as an amendment to the contract. No modification or addition to the contract shall occur by the acknowledgment or acceptance by Seller of a purchase order, acknowledgment, release or other form submitted by Buyer containing additional or different terms or conditions. 20.

No statement of agreement, oral or written, made before or at the formation of the contract shall vary or modify the written terms hereof, and neither party shall claim any amendment, modification or release from any provision hereof unless such change occurs in a writing signed by the other party and specifically identifying it as an amendment to the contract. No modification or addition to the contract shall occur by the acknowledgment or acceptance by Seller of a purchase order, acknowledgment, release or other form submitted by Buyer containing additional or different terms or conditions. 20.

No statement of agreement, oral or written, made before or at the formation of the Contract shall vary or modify the written terms hereof, and neither party shall claim any amendment, modification or release from any provision hereof unless such change occurs in a writing signed by the other party and specifically identifying it as an amendment to the Contract. No modification or addition to the Contract shall occur by the acknowledgment or acceptance by Seller of a purchase order, acknowledgment, release or other form submitted by Buyer containing additional or different terms or conditions. 20.