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KOPA®

Polyamide (PA)

2020. Nov. KOLON PLASTICS, INC. All right reserved.

HEADQUARTER

64, Gongdan 3-gil, Gimcheon-si, Gyeongsangbuk-do, KoreaTEL. +82-54-420-8371 FAX. +82-54-420-8360

www.kolonplastics.com

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Seoul

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Frankfurt

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Beijing

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TEL. +86-216-031-8169

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TEL. +86-189-1154-0624

TABLE OF CONTENTS

5 KOLON PLASTICS at a glance

7 KOPA® (PA6, PA66)

DIFFERENCES BETWEEN KOPA®6 & KOPA®66

COMPARISON WITH OTHER ENGINEERING PLASTICS

8 APPLICATIONS

10 OVERVIEW PRODUCT PORTFOLIO

13 NOMENCLATURE

14 THE PROPERTIES OF KOPA®

18 INJECTION CONDITIONS & HANDLING PRECAUTIONS

54

KOLON PLASTICS at a glance

KOLON PLASTICS always offer the best solution to customers.

KOLON PLASTICS creates a better world based on the DNA of KOLON Group,

the dream of becoming 'Lifestyle Innovator'.

KOLON PLASTICS is the only engineering plastics specialist in Korea, producing

and selling the highest-quality Base and Compound products in the world.

From POM, PA, PBT to Composite, we are building a wide range of product

portfolios around the world to 90 countries, including Europe, America, and

Japan.

KOLON PLASTICS, through the world's best technology and sustainable

research and development, will present differentiated value to customers

and continues to strengthen its global competitiveness through expansion of

overseas markets.

ESTABLISHMENTMarch 15, 1996

HEAD OFFICEGimcheon, Korea

SALES205 bil. USD (2016)

PRODUCTS8 Brands, 400 Grades

NH

hydrolysisH2N

OH

O

O

-caprolactam 6-aminocaproic acid

NH (CH2)5 - C

n

O

H O

H HD

H O

H CH

NN

Adipic Acid HexaMethyleneDiamine

+

C(CH2)4CNH(CH2)6NH

n

O O

7

KOPA® (PA6, PA66)

KOPA® from KOLON PLASTICS consists of polyamide as chemical formula (PA), PA6 and PA66.

KOPA®6 is a high-performance resin made from ring-opening polymerization of caprolactam, which is reinforced by compounding technology with different properties such as mechanical stiffness, impact resistance and heat resistance. It is widely used in automobile industry and general industry.

KOPA®66 is a material made by polymerization of HXMD (hexamethylenediamine) and APA (adipic acid) reinforced with properties such as stiffness, flame retardancy, heat resistance and chemical resistance. Widely used in automotive engine part, the electrical and electronics industry, and other areas where heat resistance is more important than PA6.

DIFFERENCES BETWEEN KOPA®6 & KOPA®66

KOPA®6 and KOPA®66 have melting points of 225°C and 260°C, respectively.

Since KOPA®6 has a high water absorption rate compared to KOPA®66, it has a tendency to decrease stiffness, but toughness increases.

KOPA®66 is a material superior in stiffness, dimensional stability and chemical resistance compared to KOPA®6.

COMPARISON WITH OTHER ENGINEERING PLASTICS

The greatest feature of the KOPA ® is its excellent mechanical strength and abrasion resistance.

In addition, KOPA® has excellent oil resistance and chemical resistance required for automotive parts and maintains a stable state in alkaline aqueous solution.

PA66 basically meets UL94 V2, and a higher flame retardant grade can be obtained by using flame retardant additive.

KOPA®

Polyamide (PA)

PA6 -NHCO-(CH2)5-

PA66 -NH-(CH2)6-NHCO-(CH2)4-CO-

98

ENGINE COVER (KN133HB20BL)

● High strength● Good surface

INSIDE DOOR HANDLE ASSEMBLY (KN133G15BL-Bracket) (KN135G15HSBL-Housing)

● Wear resistance● Weather resistance● Low gas

OUTSIDE DOOR HANDLE (KN153HB40WBL)

● Weather resistance● Excellent strength and surface

WHEEL COVER (KN333NW)

● Excellent paintability● Impact modified● UV resistance

AIR INTAKE MANIFOLD (KN133G35LH)

● High strength● Long-term heat resistance● Dimensional stability

CARRIER PLATE (KN333G35HS)

● Wear resistance● Great strength

AIR VENT WING (KN135G40WBL)

● Polyamide + GF ● Light resistance

A/T LEVER MOUNTING BRACKET (KN333G30HS)

● High strength● Heat stability● Good surface

DOOR FRAME INNER COVER (KN133G15BR)

● High strength● Excellent flowablility

NVH CYLINDER HEAD COVER (KN333HB40HSBL)

● Heat resistanceRADIATOR HEAD TANK (KN333G30CR)

● Hydrolysis resistance● Mechanical strength● Heat resistance

HEADREST GUIDE (KN136, KN131HI, KN331HI)

● High impact● Dimensional stability

APPLICATIONS

1110

OVERVIEW PRODUCT PORTFOLIO

CATEGORY GRADE NAME DESCRIPTION APPLICATION

GENERAL

STANDARD

KN111 Middle Viscosity, General Purpose Grade General Uses

KN171 High Viscosity, General Purpose Grade Casing Cap, Bracket

KN126 Middle Viscosity, Fast processing Fastener, Air Filters

KN170 High Viscosity, General Purpose Grade General Uses

KN177N High Viscosity Grade For Extrusion Fishing Net

REINFORCED

KN133G15 Middle Viscosity, Glass Fiber 15% Reinforced Grade

General Uses







IMPACTMODIFIED

STANDARD

KN131HI Middle Viscosity, Impact Modified Grade

KN163HI High Viscosity, Impact Modified Grade Safety Helmets, Outdoor Chairs

KN173HI3R High Viscosity, Extrudable Grade Pneumatic Tubes

REINFORCED

KN133G20HI Glass Fiber 20% Reinforced, Impact Modified Grade

KN133G30HI Glass Fiber 30% Reinforced, Impact Modified Grade

KN133G33HI Glass Fiber 33% Reinforced, Impact Modified Grade Junction Box

HEAT RESISTANT

STANDARDKN133HRF Heat Resistant Grade, Fast processing Wire Coating

KN133HS Heat Resistant Grade Tanks

REINFORCED

KN133G15HS Heat Resistant, Dimensionally Stable Grade Oil Reservoir Tank

KN133G35LH Heat Resistant, Hydrolysis Resistant Grade Air Intake Manifold

KN135G15HS Light Resistant, Anti-Scratch Grade Inside Door Handle

KN135G33BLHS Impact Modified Grade At Low Temperature Knobs

FLAME RETARDANT

STANDARD

KN1322V0 Halogen Free, Machinable Grade, Flame Retardant

ConnectorsKN1322V0HI Flame Retardant, Impact Modified Grade, Flame Retardant

REINFORCED KN1322G5V0 Flame Retardant, Glass Fiber 5% Reinforced Grade, Flame Retardant

SPECIAL REINFORCED

MINERAL

KN138MT30 Mineral Fiber Filled, Low Deformation

CoversKN178MT35 Mineral Fiber Filled, Low Deformation, Heat

Resistant Grade

HYBRID

KN133HB20BL Hybrid, High Heat Resistant, Dimensionally Stable Grade Engine Cover

KN133HBRR40BL Hybrid, High Heat Resistant, Dimensionally Stable, Weather Resistant Grade Outdoor Handle Grip

KN153HB40BL Hybrid, Dimensionally Stable Grade Roof Side Molding

KN153HB40W Hybrid, High weatherability Roof Rack

CATEGORY GRADE NAME DESCRIPTION APPLICATION

GENERAL

STANDARD KN3311 Middle Viscosity, General Purpose Grade General Uses

HIGH FLOW KN331F Middle Viscosity, High Flow Grade Cable Ties

LOW FRICTION KN333MS Low Friction Grade Gears, Bobbins

REINFORCED


General Uses





IMPACT MODIFIED

UNREINFORCED

KN333HI2 Middle Viscosity, Impact Modified Grade Safety Belt Parts

KN333HI4 Middle Viscosity, Impact Modified Grade Covers

KN333HI5 Middle Viscosity, Impact Modified Grade Protector, Fuse Box

KN333NW Impact Modified, Dimensionally Stable Grade Wheel Covers

REINFORCEDKN333G15HI Glass Fiber 15% Reinforced, Impact Modified Grade Relay Covers

KN333G30HI Glass Fiber 30% Reinforced, Impact Modified Grade Relay Covers

HEAT RESISTANT

STANDARD

KN333HRN Middle Viscosity, Heat Resistant Grade

KN333HS High Heat Resistant, Low Discolorated Grade, High Heat Resistant Grade Canister

REINFORCEDKN333G30HS Heat Resistant Grade Transmission Gear Supporter

KN333G35HS Heat Resistant Grade

CHEMICAL RESISTANCE REINFORCED

KN333G30CR Hydrolysis Resistant Grade Radiator Head Tank

KN333G30CRN Oil Resistant Grade

KN333G35CR High Heat Resistant, Dimensionally Stable Grade, Eg-Resistant, Dimensionally Stable Grade

Cylinder Head Cover, Coolant Temperature Control Parts

FLAME RETARDANT

STANDARD KN3322V0 Halogen Free Grade, Flame Retardant Connectors

REINFORCED

KN3321G10V0Y High Toughness, Dimensionally Stable Grade, Flame Retardant

ConnectorsKN3321G15V0 High Toughness, Dimensionally Stable Grade, Flame Retardant

KN332G30V0 Glass Fiber 30% Reinforced Grade, Flame Retardant

KN332G25VF Halogen Free, Glass Fiber 25% Reinforced Grade, Flame Retardant

KN332G35VF Halogen Free, Glass Fiber 35% Reinforced Grade, Flame Retardant

SPECIAL REINFORCED

MINERAL KN333MT30 Mineral Fiber Filled Grade Cam Shaft

CARBON FIBER KN333C22 Carbon Fiber 22% Reinforced, High Strength Grade Cylinder Piston Parts

HYBRIDKN333HB30 Hybrid, Dimensionally Stable Grade

KN333HB38 Hybrid, Dimensionally Stable Grade Engine Cover

HIGH FLOWKN333G50F Middle Viscosity, Glass Fiber 50% Reinforced, High Flow Grade

KN333G60F Middle Viscosity, Glass Fiber 60% Reinforced, High Flow Grade

KOPA®6 KOPA®66

13

NOMENCLATURE

The name of KOPA® commercial products generally follows the scheme below:

RESIN

KN1 PA6KN3 PA66KN5 Co-polymer

VISCOSITY

1 Low viscosity3 Middle viscosity5 Alloy7 High viscosity8 High viscosity9 High viscosity

CONTENT

20 20%30 30%40 40%

CHARACTERISTICS 1

1 Mold releasing2 Flame retardance3 Heat resistance5 Weather resistance7 for monofilament

CHARACTERISTICS 2

VO UL 94 flammabilityHI Impact modifiedHR Heat resistanceHS Heat stableST Super toughnessVF Halogen freeW Weather resistanceCR Chemical resistanceHF or F High flowMJ Metal jointMS Wear resistance

ADDITIVES

C Carbon fiberG Glass fiberMT Mineral TalcMC Mineral ClayHB GF/MineralNone Unreinforced

COLOR

BL BlackBK BlackBU BlueGR GrayWH WhiteGN GreenRE RedYE YellowNone Natural color

RESIN COLORCHARACTERISTICS 2CONTENTADDITIVESCHARACTERISTICS 1VISCOSITY

K V1 3 BN 2 O4 0G L

1514

THE PROPERTIES OF KOPA®

KN333G35CRCHEMICAL RESISTANCE & HEAT RESISTANCE ENHANCEMENT

It is suitable for parts requiring high chemical resistance and heat resistance. It is being applied to engine parts including automobile cylinder head covers. We offer differentiated value as below.

• Vehicle weight reduction (about 40% weightreduction, replacement of aluminum parts)

• Cost reduction (about10~15%cost reduction,replacement of aluminum parts)

• Excellentthermalstability• Goodchemicalresistancetooilsandantifreeze

KN333G35CRBKCHEMICAL RESISTANCE & ANTI-FREEZING PROPERTY ENHANCEMENT

It is the material that is suitable for the engine coolant application parts of automobile.

• Superiorthermalstability• Chemicalresistancetooilandantifreeze• SuperiorHydrolysisResistance

KN133HBRR40BNWEATHER RESISTANCE ENHANCEMENT

It is a material suitable for automotive exterior parts requiring high weather resistance.

Especially, it is widely applied to parts such as Roof Rack and has the following advantages.

• Excellentdimensionalstability• Excellentultravioletshieldingproperty• Improvedappearanceandsurfacequality• Highmechanicalstrength

Products that are reinforced with resistance to ultraviolet rays through compounding meet the requirements of the vehicle’s exterior part.

The Q-UV (313 nm) and Xenon arc evaluation show that the KN133HBRR40BN material exhibits a lower level of discoloration than the regular PA6 hybrid reinforced products.

Q-UV(313nm) TEST

- KN133HBRR40BN- Normal PA6 + GF & MF

5

4

3

2

1

01,000 2,000 3,000

△E

Time (hrs)

XENON ARC WEATHER-O-METER TEST

- KN133HBRR40BN- Normal PA6 + GF & MF

5

4

3

2

1

01,000 2,000 3,000

△E

Time (hrs)

CHANGE IN TENSILE STRENGTH WITH TIME CHANGE

- KN333G35CR- Competitor

120

115

110

105

100

95

905000 1,000 1,500

[ Temperature condition: 140°C ]

Tens

ile S

treng

th (M

Pa)

Time (hrs)

ANTI FREEZING RESISTANCE TEST

[ Temp: 120°C / Time: 720hrs / Solution: EG : H20 = 1 : 1 ]

Tens

ile S

treng

th R

eten

tion

rate

(%)

120

100

80

60

40

20

0170Initial 340 510 720

- KN333G35CRBK- Competitor

Time (hrs)

1716

KN333G50F, KN333G60FEXCELLENT FLOWABILITY

In order to improve the pro -ductivity of the injection molding process, it is a material which improves the flow of the molten resin.

KN333G35HSBLHEAT RESISTANCE ENHANCEMENT

Heat-resistant grades are suitable for high-tempe-rature parts inside the engine room, especially intercooler parts.

• Vehicle weight reduction (about 40% weightreduction, replacement of aluminum parts)

• Superiorthermalstability

KN133G35LHLONG-TERM HEAT STABILITY ENHANCEMENT

It is material that has excellent long-term heat stability. It is mainly developed for long-term exposure to high temperature such as AIM (Air Intake Manifold) parts for automobile.

• Suitableforlightweightofvehicle• Highheatresistance• Excellentchemicalresistance

Note: KOLON PLASTICS has prepared this report based on the data obtained up to the time of writing. The figures in all tables are representative values, not quality assurance values. Numerical values in the table can not be used as basic data for semi-finished product and finished product design. As the product quality improves, the figures in the table may change without notice.

TENSILE STRENGTH (MPa) 0 hr 750 hrs 1,300 hrs 2,000 hrs RETENTION RATE (%)

KN333G35HSBL 171.6 162.2 147.7 123.0 71.7

Competitor 180.9 175.8 121.5 98.3 54.4

THE PROPERTIES OF KOPA®

CONTINUOUS USE TEMPERATURE (°C)

120

110

100

90

80

70

60KN133G35LH Normal N6+GF35 Competitor

°C

[ Condition: Chamber Temp. at 200°C ]

250

200

150

100

50

0750 1,300 2,000

- KN333G35HSBL- Competitor

Tens

ile S

treng

th (M

Pa)

Time (hrs)

TESILE STRENGTH RETENTION RATE (%)

[ Temperature condition: 135°C ]

115

105

95

85

75

65

557500 1,3001,300 2,000

- KN133G35LH- Competitor- Normal N6+GF35

%

Time (hrs)

High flow PA66/G60%

High flow PA66/G50%

PA66/G60%

PA66/G50%

PA66/G40%

PA66/G30%

PA66/G20%

PA66/G10%

0 20 40 60 80 100 120 140

FLOW LENGTH (%)

[ % ]

1918

INJECTION CONDITIONS & HANDLING PRECAUTIONS

KOPA®6PRE-DRYING

KOPA®6 has a high water-absorption rate. When resin absorbs water, it causes hydrolysis during the injection molding process, resulting in degradation of properties and unsatisfactory molded parts. Therefore, pre-drying is essential prior to injection molding. Drying equipment may include a hot-air dryer or a dehumidified dryer, the latterbeingmoreefficient.Normally,adehumidifieddryeroperated4to6hoursatatemperatureof75~85°Cwill reduce water content to 0.1% or lower.

KOPA®66PRE-DRYING

KOPA®66 resin is kept at max. 0.2% moisture content in packages. However, it is apt to absorb moisture during processing work. Therefore, processing should be completed in less than two hours after the package is opened. Once moisture is absorbed, the resin must be dried by means of a hot-air dryer or dehumidifying dryer. Normally,thelatterisbetter.Dryingnormallyrequires5hoursat70~80°C.

EXTRUSION MOLDING

KOPA®6 has very low melt viscosity and is highly sensitive to temperature changes. Generally, a temperature of 15~60°Cabovethemeltpointshouldbemaintained.ConsiderationshouldalsobegiventothefactthatKOPA®6 is highly water-absorbent and its residual monomer is easily melted down. Being affected by moisture, extrusion molded parts may contain bubbles and result in degradation of mechanical properties, and the lowered melt viscosity caused by the residual monomer, which adhere to the die mouth or its surroundings and the part itself after being extruded from die in a sublimate. This may produce defective molded products. Therefore, moisture content must be controlled at 0.1% or lower, the residual time inside the extruder must be minimized, and a die without dead space should be used.

INJECTION MOLDING INJECTION MOLDING

CONDITIONS OF INJECTION MOLDING

SELECTION OF INJECTION MOLDING MACHINE

For molding KOPA®6, a screw-type injection molding machine works best, with a minimum 20 L/D screw and a compression ratio of 3-4, and a chrome-plated nitrogenous steel base. As KOPA®6 has such low viscosity when melted, compared with other resins, this may cause reverse flow of molten polymer. Therefore, the injection molding machine must be equipped with a screw head having a reverse-flow blocking valve. It is also advisable to use an intermittent nozzle to prevent nozzle drool.

TEMPERATURES OF CYLINDER & NOZZLE

Resins are melted by the heater located inside the cylinder and by the share stress generated between the screw and cylinder barrel. Generally, the bottom side of a hopper is sufficiently cool for smooth transportation of pellets. The melting zone is set at a temperature suitable for melting down resins, and the nozzle area is set a temperature 10°C lower than the melting zone, thus preventing nozzle drool. If the temperature of the melting zone is too high, thermal degradation and substance volatility can occur, causing bubbles or silver streaks in the produced part. Conversely, if the temperature of the melting zone is too low, the flowability of the resin is reduced. This necessitates excessive injection pressure, thus degrading the properties of the produced part.

SELECTION OF INJECTION MOLDING MACHINE

In is preferable to adopt in-line screw and screw-plunger type, as these are advantageous for melting power, temperature adjustment, prevention of material loss, and speedy internal pressure formation.

PRESSURE

If injection pressure is too low, part structure will be defective, and if too high, the resin layer floats during cooling, or causes deviation in structure or density, and/or easy breakage or damage from stress.

MOLD TEMPERATURE

Mold temperature affects product appearance and the accuracy of product dimensions, and has a direct effect on productivity due to shortened cycles. If the mold temperature is too low, productivity increases due to faster cooling, but cosmetic and mechanical properties are degraded due to reduced material flow. It is essential to set the proper mold temperature necessary to maintain properties as required by the particular product specification, because KOPA®6 is a crystalline polymer, and crystall ization varies based on cooling speed. (Normally, the mold temperature of KOPA®-PA6 should besetat60~80°C) If themold temperature isuneven,product warpage can occur.

INJECTION PRESSURE

Molten polymer flows through the mold cavity under the force of injection pressure, and a considerable amount of pressure is lost as material flows through the narrow sprue, runner, gate, etc. Normally, the pressure applied to thecavitymayrequireabout300~500kg/cm2 per projected area of the produced part. If injection pressure is too great, residual stress is increased due to over-charge that can cause horizontal strength degradation. If the pressure is too low, it can cause short shots, shrinkage, and bubbling. Also, in order to compensate for the volume decrease incurred during material cool-off, a holding pressure of 30~80%oftheinitialinjectionpressureisrequired.

MOLD TEMPERATURE

Temperature is adjusted in accordance with the structure of parts and specification of injection molding machines. The resin melts at 260°C, and standard grade is maintainedat265~280°C,whereasa10~20°C increasein temperature is applied for glass fiber reinforced grade. Resin properties may be degraded if the temperature is too high and/or injection time is too long.

TEMPERATURE OF MOLD

Mold temperature is adjusted between 40°C and 80°C depending on the required property of molded parts. Cosmetic and mechanical properties of parts can be improved by increasing mold temperature.

INJECTION MOLDING PARAMETERS

UNFILLED KOPA®6

REINFORCED < 15% KOPA®6

REINFORCED> 15% KOPA®6

UNFILLED KOPA®66

REINFORCED KOPA®66

Recommeded Moisture Contents (%) ≤ 0.1

Melting Temperature (°C) 225 225 225 260 260

Cylinder Temperature (°C)

Nozzle 235~260 245~270 260~290 275~280 280~310

Front 235~265 245~275 260~290 275~285 280~310

Middle 235~260 240~260 250~280 270~280 270~305

Rear 220~240 230~240 240~255 260~275 270~290

Mold Temperature (°C) 40~70 60~80 60~90 50~80 60~100

Holding Pressure (%) 1/3~2/3ofmax.injectionpressure

Cushion (mm) 5~10

kolon plastics always offer the best solution to customers

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