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2006-12-05 News Release

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Pocan XF increases productivity for plastics molding

The low density of Pocan XtremeFlow reduces cycle times in injection molding and produces plastics components that are lighter and resistant to thermal aging.

Easy-flowing Pocan* XF polybutylene terephthalates (PBT) from LANXESS increase productivity in injection molding and offer significant savings. A case in point is the range of three-part lamp sockets manufactured by the Italian lighting components producer LUCE. “XF” stands for XtremeFlow.

Find Information and Suppliers of polybutylene terephthalates.

“When producing lamp parts, we have been able to cut melt temperature by 15 °C compared with a standard PBT previously used, and have also significantly reduced component wall thicknesses. As a result, cycle times have been cut by 12 to 15 percent,” explains Renato Burel, Managing Director of the company based in Montescudo, near Rimini. “Thanks to the low density of Pocan XF, the components were also up to five percent lighter.”

Easy-flow Pocan* XF for lamp socket components. Click Go for High resolution image. photo: Lanxess

The three-part lamp holder is made up of an Edison screw lamp socket, cable feed, and a fitting ring to clamp the lamp shade firmly in place. All the parts must have a low flammability rating. Consequently, the plastics for these non-conductive lamp components must exhibit a glow-wire temperature (GWT) of at least 650 °C in accordance with IEC 60695-2-11. Pocan XF achieves a value of 750 °C in this test. This not only means greater safety, but also represents a major improvement on the performance of standard PBT.

It is especially important that Pocan XF is highly resistant to thermal aging. The lamp parts were accordingly stored at a temperature of 215 °C for 168 hours as per the EN 60238 standard and then subjected to a range of mechanical toughness tests. These tests resulted in only very minimal deformation that still allowed a light bulb to be fitted easily. The cable guide also remained firmly attached to the socket.

LANXESS offers Pocan XF with 20 and 30 percent glass-fiber reinforcement. Both materials enable up to 30 percent longer flow paths than comparable general-purpose PBTs. This high flowability enables the use of much simpler molds with fewer gates. It also extends the scope for processing. As a result, the melt temperature for existing molds can be reduced, thereby also cutting cycle time and increasing cost efficiency in production. Alternatively, injection pressure can be reduced to prevent the cores from moving in the mold. This is ideal for manufacturing components with finely structured and delicate geometries, for example. Lowering the injection pressure also enables the processor to switch to smaller injection molding machines, thereby providing greater freedom in machine selection and production planning.

LANXESS envisions huge application potential for Pocan XF in the electrical, automotive and domestic appliance industries – for example plugs, edge connectors, PCBs, housings for central electrical systems and transmission plates subjected to high mechanical load.

* Pocan XF is a trademark of Lanxess.

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