table of contents - kolon plastics...kolon plastics is the only engineering plastics specialist in...

TABLE OF CONTENTS

5 KOLON PLASTICS at a glance

7 KOCETAL® (POM)

CHARACTERISTIC OF KOCETAL®

8 APPLICATIONS

10 OVERVIEW PRODUCT PORTFOLIO

11 NOMENCLATURE

12 THE PROPERTIES OF KOCETAL®

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

7

KOCETAL® (POM)

KOCETAL® is a copolymer type polyacetal resin with excellent anti-friction / anti-wear, chemical resistance, heat-resisting sta-bility, precise dimensions and molding abilities.

It is used for various purposes in the fields such as automobiles, office equipment, and household items.

CHARACTERISTIC OF KOCETAL®

MECHANICAL PROPERTYKOCETAL® is highly crystalline and has excellent balance of mechanical toughness and rigidity. It is also resistant to fatigue, creep, and has good wear and abrasion resistance by its self-lubricating property. However, due to a glass transition temperature about -60°C, the change in mechanical properties with temperature is relatively large.

THERMAL STABILITYKOCETAL® is more thermally stable than homopolymers. Since the crystalline resin, KOCETAL®, does not cause significant deformation even over the thermal deflection temperature. By the addition of various stabilizers, the thermal properties of the KOCETAL® can be improved.

CHEMICAL RESISTANCEKOCETAL® is resistant to general organic solvents due to its high crystallinity. Although it has excellent chemical resistance to gasoline and lubricating oil, adding acidic additives to improve performance may make insufficient chemical resistance.

WEATHER RESISTANCEPolyacetal resins are not good resistance to UV rays, but KOCETAL® can be reformed by prescribing light stabilizers and UV rays absorbers.

KOCETAL®

Polyoxymethylene (POM)

98

LUMBAR SUPPORT (K300EW, K300LO, UR302LO)

Injection moldability Dimensional stability

WINDOW MOTOR GEAR (K100HS)

Friction resistance Creep resistance Dimensional stability

DOOR LATCH HOUSING (K300EWBBK)

Dimensional stability Wear resistance Good strength

FUEL PUMP ASSEMBLY (K100HS, K300EW)

Creep resistance Dimensional stability

SANITARY PART (K300)

Good strength Chemical resistance Hydrolysis resistance

GEAR (LF301, K300, K300EW, GF305)

Low friction Creep resistance Dimensional stability

EXTRUDED ROD (K100)

Heat stability Control of crystallizaition Dimensional stability

FASTENER (UR304)

Optimized toughness and strength

Excellent color stability

SPEAKER GRILL (WR701LO)

Excellent UV- resistance

Low Formaldehyde gas emission

Good flowability

BUMPER BRACKET (K300EWBBK, K300HBK)

Excellent dimensional stability

Optimized toughness and strength

Good chemical resistance

SEAT BELT BUTTON (K300HRD)

Weather resistance Dimensional stability

APPLICATIONS

1110

OVERVIEW PRODUCT PORTFOLIO

CATEGORY GRADE NAME DESCRIPTION

GENERAL

K100 Unreinforced Grade (MI: 3)


K300EW Unreinforced, Slight Ductility Grade (MI:9)




HIGH STRENGTHK100HS High Strength, Unreinforced Grade (MI: 3)

K500HS High Strength, Unreinforced Grade (MI: 14)

LOW VOC

K100LO Low VOC, Unreinforced Grade (MI: 3)



K100HSLO Low VOC, High Strength Grade

K500HSLO Low VOC, High Strength Grade

UR302LO Low VOC, Impact Modified Grade

UR304LO Low VOC, Impact Modified Grade

WR301LO Low VOC, Impact Modified Grade (MI: 9)

WR701LO Low VOC, Impact Modified Grade (MI: 27)

WEATHER RESISTANT

WR301 Light Resistant Grade (MI: 9)

WR701 Light Resistant Grade (MI: 27)

WR303 Outdoor Weather Resistant Grade (MI: 9)

IMPACT MODIFIED

UR302 Impact Modified Grade with TPU

UR304 Impact Modified Grade with TPU

EL302 Impact Modified Grade with TPEE

EL304 Impact Modified Grade with TPEE

REINFORCED

GF305 Glass Fiber 25% Reinforced Grade



GB705 Glass Bead 25% Reinforced Grade

TC704 Talcum 20% Reinforced Gradee

WH704 Whisker 20% Reinforced Grade

LOW WEAR &

FRICTION

MS301 Low wear, Low Friction Grade with MoS2

SO301 Low wear, Low Friction Grade with Silicon Oil

TF302 Low wear, Low Friction Grade with PTFE 10%

TF304 Low wear, Low Friction Grade with PTFE 20%

LF301 Low wear, Low Friction Grade

LF302 Low wear, Low Friction Grade

LW301 Low wear, Low Friction Grade

LF701 High flow, Low Wear, Low Friction Grade

LW701 High flow, Low Wear, Low Friction Grade

SW501HS Low wear, Low Friction Grade

CONDUCTIVE

CB301 Conductive Grade with Carbon Black

CF702 Conductive, Reinforced Grade with Carbon Fiber

CN301C3 Conductive Grade with Carbon Nano Tube

SPECIAL

DS500HS Hot Diesel Resistant Grade, Acid Resistant Grade

K300PW General Grade for Applications Where Drinking Water Approval is Prerequisite.

VT702 Anti-Static Grade

NOMENCLATURE

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

CONTENT

1 5%2 10%3 15%4 20%5 25%6 30%8 40%

CHARACTERISTICS 2

EW Slight ductility grade than standardHS High strength gradeLO Low odor and VOC’s gradePW Potable water

COLOR

BE BeigeBK Pre colored blackBBK Salt and pepper type blackBL BlueBN BrownDG Dark grayGR, GY GrayRD RedWT WhiteYE YellowNone Natural

CHARACTERISTICS 1

K Standard gradeCB Conductive grade with special carbon blackCF Conductive grade with carbon fiberDS Hot diesel resistance improved gradeEL Impact modified grade GB Glass filled gradeGF Highly stiff grade with glass fiberLF Low friction grade with special polymerLW Low wear grade with special polymerMS Low friction grade with MoS2

SO Low friction grade with Silicon OilTC Talcum filled grade for dimensional stabilityTF Low friction grade with PTFEUR Impact modified gradeVT Anti-static gradeWH Whisker filled grade for low friction and high stiffnessWR Weather resistance improved grade

VISCOSITY

10 MI = 3 (High viscosity)30 MI = 9 (Medium viscosity)50 MI = 14 (Medium viscosity)70 MI = 27 (Low viscosity)90 MI = 45 (Very low viscosity)

CHARACTERISTICS 1 VISCOSITY CONTENT CHARACTERISTICS 2 COLOR

K - 3 0 0 L O B K

1312

THE PROPERTIES OF KOCETAL®

KOCETAL® FOR AUTOMOTIVE

KOCETAL® is stable in a wide temperature range from -40°C to 100°C.

KOCETAL® is suitable for auto-motive interiors since it has excellent chemical resistance to washers, antifreeze, gasoline, diesel and so on.

KOCETAL® FOR E&E, INDUSTRIAL APPLICATIONS

KOCETAL® is widely used for high - per formance par ts for electric / electronic applications requiring high precision and functionality.

KOCETAL®, produced by cry-stallization control technology, has fast crystallization, dense and uniform crystal structure. It implements excellent abrasion resistance and high mechanical strength suitable for various office equipment and electric / electronic parts

For extrusion applications, K100, which has a slower crystallization rate, is widely used and K300 is the most commonly used for general injection molding.

K100HS is crystallized quickly and at the same time it produces small and constant crystals which show excel lent wear resistance and high mechanical strength. It is a material suitable for high-load gears and driven parts.

KOCETAL® is suitable for auto-motive interiors since it has super ior color stabi l i t y and weather resistance.

It also has low formaldehyde emission over a wide range of molding temperature.

CHEMICAL RESISTANCE OF KOCETAL® K300

DIESEL IMMERSION TEST OF KOCETAL® K300

WEAR RESISTANCE

DEGREE OF CRYSTALLIZATION BY GRADES

[ unit: ppm ]

CHEMICALS WEIGHT LOSS DIMENSION CHANGE

CHANGE OF TENSILE STRENGTH

GASOLINE 0.45 0.15 1.54

KEROSENE 0.19 0.02 4.62

LIGHT OIL 0.10 0.01 3.08

ENGINE OIL - 0.50 - 0.06 4.62

BREAK OIL 0.87 0.27 0.00

GLASS WASHING ANENT 0.74 0.20 3.08

[ Condition: 23°C, 1 year-immersion, unit % ]

TEST CONDITION K300LOW ODOR MATERIAL

K300LO WR301LO

65°C x 2 hours < 1.45 < 0.04 No detection

80°C x 2 hours < 1.45 < 0.07 < 0.04

100°C x 2 hours < 1.45 < 0.18 < 0.18

240°C x 15 minutes - < 60.0 < 90.0

VDA 275 (60°C x 3 hours) < 8.70 < 0.70 < 0.50

REMARK STD STD UV resistance

[ Condition: 120°C, 520hr ]

DS500HS K300

Rete

ntio

n (%

)

120

100

80

60

40

20

0Tensile strength Elongation Impact strength

[ Condition: Pressure - 1.5kg/cm2, Speed - 30cm/s (Same body) ]

Specific wear Specific wear (Counter part) Coefficient of dynamic friction

Spec

ific

wea

r (m

3 /kg

km)

320

240

160

80

0Competitor LF301 K300

- K100- K300- K100HS

Crys

talli

zatio

n ha

lf tim

e (m

in.)

40

30

20

10

0

Isothermal temperature (°C)

149 150 151 152 153 154 155

1514

MECHANICAL PROPERTIES

KOCETAL® is a material that has better mechanical strength and durability than PA and PBT. In addition, it has excellent impact resistance, heat resistance and weather resistance.

CREEP RESISTANCE

KOCETAL® is an excellent creep resistant material. It is widely used for various types of valves, including buckles.

FATIGUE RESISTANCE

KOCETAL® has excellent elastic recovery and fatigue resistant properties. These properties are used in materials such as zippers and tape reels.

WEAR RESISTANCE, LOW FRICTION

KOCETAL® is a self-lubricating material with exceptional anti-friction / wear characteristics compared to o the r p l as t i c materials.

DIMENSIONAL STABILITY

KOCETAL ® reaches a stable condition after 24 hours at room temperature af ter injection, without further deformation.

Due to low water absorption and dimensional stability, it is suitable as a material for high-precision parts due to small change in dimensions.

ELECTRICAL PROPERTY

With i ts super ior e lectr ica l p r o p e r t i e s i n c l u d i n g h i g h insulation, Kocetal is featured w i t h l o w t e m p e r a t u r e dependency on res is t i v i t y, electric permittivity, dissipation f a c t o r a n d t h e D i e l e c t r i c Strength.

HOT WATER RESISTANCE

KOCE TAL ® can be adopted f o r t h e p r o d u c t s u s e d i n h igh temperature / humid i t y environments as there is less d i m e n s i o n a l a n d m a te r i a l property change in hot water immersion tests, compared to acetal homopolymer, nylon or PBT resin.


CREEP RESISTANCE OF KOCETAL® K300

[ Condition: 80°C in air ]

Stra

in (%

)

12

10

8

6

4

2

0

Holding time (hr)

10-1 100 101 102 103

- 200kg/cm2 - 150kg/cm2 - 100kg/cm2 - 50kg/cm2

[ Condition: 23°C in air ]

Stra

in (%

)

3.0

2.5

2.0

1.5

1.0

0.5

0.0

Holding time (hr)

100 101 102 103 104

- 200kg/cm2 - 150kg/cm2 - 100kg/cm2 - 50kg/cm2

WEAR RESISTANCE, LOW FRICTION

[ Condition: Pressure 0.6kg/cm2, Speed: 15cm/sec, Same body ]

Coef

ficie

nt o

f dyn

amic

fric

tion

0.8

0.6

0.4

0.2

0K300 MS301 PBT ABSPC

0.270.21

0.47

0.65

0.43

Coefficient of dynamic frictioncompared to other plastics

Coef

ficie

nt o

f dyn

amic

fric

tion

0.4

0.2

0K300

vsK300

K300vs

GF705

K300vs

PA6

K300vs

PA66

K300vs

PBT

K300vs

Steel

0.27

0.32

0.230.20

0.13

0.23

Coefficient of dynamic ofK300 against other plastics

ELECTRICAL PROPERTY

Diss

ipat

ion

fact

or

[ Test material: K300 ]

0.05

0.04

0.03

0.02

0.01

0

Temperature (°C)

-50 0 50 150100

1KHz

MHz

Dissipation factorby temperature

HOT WATER RESISTANCE

[ Immersion temp: 100°C ]

- Homo-POM - PBT - PA6 - PA66 - Kocetal K300

Rete

nsio

n of

tens

ile s

tren

gth

(%)

140

120

100

80

60

40

20

0

Immersion time (hr)

600100 200 300 400 500

Retension of tensile strengthby hot water immersion

DIMENSIONAL STABILITY

Mol

d sh

rinka

ge (%

)

3

2

1

0

[ Product: 80 x 80 x 3mm(plate), Mold temp: 80°C ]

Cylinder temp. (°C)

Kocetal K300(190)

PBT(240)

PA6(240)

PA66(250)

PC(250)

ABS(240)

Mold shrinkage compared toother plastics

[ Test material: K300 ]

Stra

in (%

)

0.6

0.5

0.4

0.3

0.2

0.1

00.5 1.0 2.01.5

Water absorption (%)

Change of dimensionby water absorption

FATIGUE RESISTANCE

Heat

dis

tort

ion

tem

pera

ture

(°C)

250

200

150

100

50

0Kocetal K300 PA6 PA66 PBT

4.6kg/cm2 18.6kg/cm2

Heat distortion temp. compared to other plastics

- PC - PA6 - K300 - Homo-POM

Fatig

ue s

tren

gth

(kg/

cm2)

800

500

400

200

0

Number of cycles to failure

1.0 x 105 1.0 x 106 1.0 x 107

1716


THERMAL STABILITY

K O C E TA L ® h a s i m p r o v e d therma l s t ab i l i t y, which is the weakness of most POM materials. As a result, it brings the following features

env i ronment due to less formaldehyde emission

gement cost due to mold contaminant reduction and q u a l i t y i m p r o v e m e n t o f molding products

in in ject ion equipment or decrease in physical properties and discoloration even in the case of the use of pulverizing agent.

applications of parts exposed to external environment by improvement of weather resistance and ultrav io let resistance.

WEATHER RESISTANCE

When products made f rom conventional acetal resins are left outdoor for 6 months, aging will cause discoloration, surface cracking and degradation. In env i ronments where there i s p r o l o n g e d ex p o s u re to sunlight and ultraviolet rays, we recommend the use of UV resistant grades. However if exposure is not excessive it is possible to use standard grades.

CHEMICAL RESISTANCE

KOCETAL® is highly resistant to organic compounds, oils, fats and synthetic detergents.

CHEMICAL RESISTANCE

KOCETAL Homo-POM PBT PA PPO PC

SOFT ACID O O

STRONG ACID X X X O

SOFT ALKALI O O O O O

STRONG ALKALI O X X O O X

AROMATIC O O O X X

HALOGEN O X X

ALCOHOL O

ESTER O O O X X

KETONE O O O O O X

OIL O O O O

: Excellent O : Usable : Usable with caution X : Not usable

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. The figures in the table can not be used as basic data for semi-finished products and finished product designs. As product quality improves, figures in the table may change without notice.

WEATHER RESISTANCE

- Fade-o-meter, 83°C, withsout rain- Weather-o-meter, 83°C, withsout rain

Yello

w in

dex

100

80

60

40

20

0

Time (hr)

200 400 600 800 1,000 1,200

KocetalK300

KocetalWR301

Rete

nsio

n of

tens

ile s

tren

gth

(%)

140

120

100

80

60

40

20

0

[ Condition: 83°C, without rain ]

Time (hr)

200 400 600 800 1,000 1,200

- Homo-POM - PA6 - Kocetal K300 - Kocetal WR301

THERMAL STABILITY

[ Air flow: 300m2/min, Condition: 240°C on Air ]

- Homo-POM - Other co-POM - Kocetal K300

Rate

of r

emai

ning

wei

gh (%

)

100

80

60

40

20

0

Heating time (hr)

20 40 06 80 100 120

TGA thermogram

-12

-13

-14

-15

-16

-17

Cylinder temperature (°C)

240200 210 220 230

Yello

w in

dex

0-2-4-6-8

-10-12-14-16

Holding time (min)

1000 20 40 8060

Yello

w in

dex

- Other co-POM - Kocetal K300

Wei

ght l

oss

(%)

2

1.6

1.2

0.8

0.4

0

Aging temperature

200°C 220°C 240°C

[ Condition: aging for 30mins. ]

1918

INJECTION CONDITIONS & HANDLING PRECAUTIONS

PRE-DRYING

KO C E TA L ® i s a p o l yacet a l copolymer and its absorption rate is low.It can be used without pre -liminary drying even after left in the open state, and there is no fear of decomposition by moisture absorption. However, we recommend pre - d r y ing i f the re i s a p oss ib i l i t y o f appearance defects such as silver tones.

DRYING CONDITION

GENERAL CASE

Heated-air drying at 80°C x 3 hours or more

IN CASE OF MOLDING DEPOSIT

Heated-air drying at 100°C x 3 hours or more

PYROLYSIS AT HIGH TEMPERATURE

Keeping KOCETAL® resin at a temperature higher than 250°C or staying in the cylinder for more than 230°C for a long time (more than 30 minutes) may cause generation of formaldehyde gas and discoloration of resin due to thermal decomposition of resin.

PYROLYSIS PREVENTION GUIDE

molten resin below 230°C.

stopped for a long time, purge the molten resin in the cylinder then stop the operation.

and delayed, lower the cylin-der temperature to the level of 165°C.

rials avoid moisture absorption and contamination.

INJECTION MOLDING

The optimal molding conditions o f K O C E T A L ® s h o u l d b e determined in consideration of the flow characteristics of the resin, molding shrinkage, d i m e n s i o n a l a c c u r a c y , and qual i t y stab i l i t y of the molded product, uniformity, and economic ef ficiency. In particular, it is necessary to rev iew al l these condit ions before molding.

T he in jec t ion tempera tu re should be set slightly higher than the theoretical KOCETAL® melting point of 165°C and it is recommended to use below 220°C in order to suppress the generation of formaldehyde gas due to pyrolysis.

I n g e n e r a l , m o l d i n g s t h a t require thin or multiple cavities and/or dimensional accuracy should be injected quickly, and thicker products that may cause p rob lems such as bubb les should be injected slowly. The cooling time should be set not to appear deformation or pin marks when the molded product is taken out.

USE OF RECYCLED MATERIALS

KOCETAL® can be mixed with recycled materials. However, in order to obtain a high-quality molded product, be aware of the following points.

5 times, there is no big change in physical pro-perties.

tends to decrease slightly, and there is not much change in fluidity.

determined by the color change.

recycled materials.

plasticized and may cause defective molding.

CHANGE MATERIAL

Purging the cylinder using PP (polypropylene) resin or PE (polyethylene) resin. In particular, when molding resins with different molding temperatures, it is recommended that the cylinder be cleaned.

DISCONTINUE THE OPERATION

If you stop the operation for a long time (more than 1 hour), you should purge the cylinder and set the cylinder temperature below the melting point (165°C).

CONDITIONS OF INJECTION MOLDING

INJECTION MOLDING PARAMETERS GENERAL POM LOW VOC POM REINFORCED POM

Recommeded Moisture Contents (%) 0.1

Melting Temperature (°C) 165 ± 5 165 ± 5 165 ± 5

Cylinder Temperature (°C)

Nozzle 185 ~ 195 180 ~ 190 190 ~ 190

Front 180 ~ 200 180 ~ 195 185 ~ 200

Middle 175 ~ 190 175 ~ 190 180 ~ 195

Rear 165 ~ 175 165 ~ 175 165 ~ 180

Mold Temperature (°C) 60 ~ 90 60 ~ 90 70 ~ 90

Holding Pressure (%) 1/3 ~ 2/3 of max. injection pressure

Cushion (mm) 5 ~ 10

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