Ultradur®

Polybutylene terephthalate (PBT)

BASF Plasticskey to your success

2

Ultradur®

Ultradur® is BASF’s trade name for its line of partial-

ly crystalline saturated polyesters. This line is based

on polybutylene terephthalate and is employed in

applications demanding a high performance level

such as load bearing parts in different industrial

sectors. Ultradur® is outstanding for its high rigid-

ity and strength, very good dimensional stability,

low water absorption and high resistance to many

chemicals. Moreover, Ultradur® exhibits exceptional

resistance to weathering and excellent heat aging

behavior.

04 - 09

10 - 23

24 - 39

ULTRADUR®, A HEAVY-DUTY MATERIAL…

… in automotive engineering

… in electrical engineering and electronics

… in precision and mechanical engineering

4

6

8

THE PROPERTIES OF ULTRADUR®

Product range

New in the product line: Ultradur® High Speed

Mechanical properties

Tribological properties

Thermal properties

Electrical properties

Fire behavior

Resistance to chemicals

Behavior on exposure to weather

10

14

19

20

21

23

THE PROCESSING OF ULTRADUR®

General notes

Injection molding

Extrusion

Fabrication and finishing processes

24

27

34

38

GENERAL INFORMATION

Safety notes

Delivery and storage

Ultradur® and the environment

Quality management certification

Ultradur® Nomenclature

Colors

Subject Index

The product range of BASF plastics at a glance

40

41

42

43

40 - 43

4

Ultradur® demonstrates its strengths wherever high-

quality and above all heavy-duty parts are required –

for example in the automotive industry. Ultradur®

is rigid, impact-resistant, dimensionally stable, heat-

Ultradur® is employed in housings and functional parts in electric

drives, housings and mountings for various electrical and electronic

components, in windscreen wiper arms, door handles, headlamp

structures, mirror systems, connectors, sun-roof components, in hous-

ings for locking systems and in many other applications.

Ultradur® in automotive engineering

Mirror acuator housing

proof, weather-resistant and resistant to fuels and

lubricants. These properties have made Ultradur®

an indispensable ma terial in many applications in

modern automotive engineering.

Headlamp

Clip

Plug-in connectorSliding roof frame

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Ultradur® is used in plug-in connectors, connector strips, switching

systems, housings for automatic cutouts, capacitor pots, in coil formers,

lamp parts, PC fans, power supply components, parts for electric drives,

sheathing for waveguides and many other products and not least in

vehicle electrical systems ( ignition coil housing).

Steering angle sensor

6

Ultradur® in electrical engineering and electronics

Parts which are becoming ever smaller and more

complex and offer steadily increasing functionality

are typical of the high demands imposed on the

materials used in electrical engineering and elec-

tronics. This is no problem for Ultradur®. It is rigid,

flame and heat resistant, it exhibits good dimen-

sional stability and outstanding long-term electrical

and thermal performance.

loose buffer tubes for optical fibers

7

Circuit breaker

Mechatronic control unit

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Ultradur® is employed in functional parts for printers, copying equip-

ment, cameras and optical devices, gas meter housings and housings

for valves, pumps and a wide variety of other applications.

8

Plug-in connector

Ultradur® in precision and mechanical engineering

long service life, perfect operation and dimensional

accuracy are properties which turn a modern com-

ponent into a first-class product.

Ultradur® contributes to this. It affords good sur-

face quality and dimensional stability, high rigidity,

compressive strength and it has particularly low

warpage.

Bristles

9

Dial caliper

Shower head

Pump pressure housing

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The Ultradur® grades are polyalkylene terephthalate

molding compounds based on polybutylene tere-

phthalate. The chemical structure is illustrated in the

following structural formula:

The properties of Ultradur®

New in the product line: Ultradur® High Speed – more efficient with nanotechnology

New in the Ultradur® product line is the rheologically modified Ultradur®

High Speed, one of the first engineering plastics whose flowability was

markedly improved through the addition of nanoparticles. Ultradur®

High Speed – created primarily for injection molding – reduces the

injection pressures and cycle times, thus achieving considerable cost

benefits during processing.

Nanotechnology is the keyThe key to this innovation lies in the admixture of an additive of finely

dispersed nanoparticles. They have made it possible to significantly

lower the melt viscosity of Ultradur® (Fig. 1). The particle size of the

additive ranges from 50 to 300 nanometers in the case of Ultradur®

High Speed. The structural viscosity remains constant while the melt

viscosity decreases by about 50 % in an Ultradur® containing 30 %

glass fibers. Therefore, depending on the fiberglass content, the new

Ultradur® High Speed flows at least twice as far as comparable stan-

dard PBT types. The mechanical properties regarding stiffness and

strength, shrinkage behavior and thermal stability under heat are not

affected by this modification.

A plus for processorsOwing to the lower melt viscosity, it is sufficient to use lower injec-

tion and holding pressures. During the injection-molding process, the

reduction in the melt temperature makes it possible to shorten the

cooling time and thus the total cycle time. The low-viscosity Ultradur®

High Speed can flow into even finer molds, so that it can be employed

to produce completely new components.

Product range

The most important applications of Ultradur® are automotive

engineering, electrical engineering, electronics and telecommunications

as well as precision engineering and general mechanical engineering.

The most varied products from the Ultradur® range are used for imple-

menting these applications. When selecting the most suitable types for

your specific purpose our technical marketing will be glad to help.

O O

C– –C–O–CH2–CH2–CH2–CH2–O

n

Visc

osit

y [P

a·s]

Shear rate [1/s]

10 100 1000 10000 1000001

100

1000

10

10000

B 4300 G6 Standard 265 °C B 4300 G6 Standard 255 °C

B 4300 G6 Standard 275 °C

B 4300 G6 High Speed 255 °C

B 4300 G6 High Speed 275 °C B 4300 G6 High Speed 265 °C

Fig. 1: Under the same shear, Ultradur® High Speed exhibits a much

lower viscosity than standard PBT

Ultradur® is produced by poly con densation of tere-

phthalic acid or dimethyl terephthalate with 1,4 -

butanediol using special catalysts. Terephthalic

acid, dimethyl terephthalate and 1,4 -butanediol are

obtained from petrochemical feedstocks, such as

xylene and acetylene.

11

A filling study (Fig. 2) shows that the very thin webs of the small plug

weighing just 1.5 grams are not filled with standard PBT (shown on the

left ) while they are filled very well with the easy flowing Ultradur® High

Speed (shown on the right). Even thin-walled components having a

greater content of reinforcement materials such as glass fibers or min-

eral fillers can be manufactured using the new easy-flow Ultradur® High

Speed. This translates into fundamentally better mechanical properties

along with thinner walls. The entire configuration of the machine can be

streamlined: smaller injection-molding units, molds with fewer injection

points, in other words, fewer expensive hot runner nozzles.

Preferred applications: automotive electronicsAnother advantage of Ultradur® High Speed comes to the fore in the

production of electronic components for cars. ABS housings, for

instance, are manufactured by overmolding metal circuit-board conduc-

tors with polymer. The higher the pressure acting on the circuit-board

conductors, the greater the risk that they will be bent or compressed,

thereby losing their functionality. Thanks to its improved flowability,

Ultradur® High Speed lowers the pressure that is exerted on the circuit-

board conductors during the injection-molding process, reducing the

deformation of the circuit-board conductor (Fig. 3).

Easy to colorUniformly distributed nanoparticles are also the reason why Ultradur®

High Speed can be homogeneously colored with less color batch. As

shown in Figure 4, homogeneous coloring can already be attained with

0.1 % of a masterbatch based on blue PE.

Fig. 2: Whereas standard PBT ( left ) does not completely fill the compo-

nent (arrow ), Ultradur® High Speed manages to completely fill the webs

Fig. 3: The flowability of Ultradur® High Speed ( right ) is also advanta-

geous for overmolded circuit-board conductors: the undesired misalign-

ment is largely suppressed

Fig. 4: Comparison of the masterbatch distribution: left (0.1 % blue in

Standard PBT 30 % GF), right (0.1 % blue in B4300 G6 High Speed)

In comparison to conventional Ultradur®, up to 50 percent less mas-

terbatch can be used with Ultradur® High Speed while still obtaining

the same color depth. The pigments are better dispersed and the color

distribution is more uniform. This effect can also be seen in terms of

the coating properties since a more homogeneous color impression is

achieved using the same amount of pigment. Moreover, lasers can be

used to write on all grades of Ultradur® High Speed that are dyed black.

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Better adhesionThe adhesion of Ultradur® High Speed to soft components as well as

to metal during chemical electroplating is considerably better than with

a standard PBT. The adhesion in N /mm is almost twice as high for the

material combination of Ultradur® High Speed and TPU than with con-

ventional Ultradur® (Fig. 5).

Economically and environmentally advantageousThe Swiss Federal University of Technology in Zurich, Switzerland ( ETH

Zürich) has quantified the economic as well as environmental advan-

tages of this new material. Owing to the good flowability, the manu-

facture of injection-molded parts is not only cheaper but also helps to

save energy and to carefully treat the environment (Fig. 6).

Envi

ronm

enta

l bur

den

[sta

ndar

dize

d]

Costs [standardized]Standard PBT Ultradur® High Speed

1.3 1.0 0.71.3

1.0

0.7

Fig. 6: Eco-efficiency analysis of Ultradur® High Speed in comparison

to standard PBT

0

2

4

6

8

10

12

14

0,5 1,0 1,5

1,0

0,8

C 85 A 15HPM

C 65 A 15HPM

B 4300 G6High Speed

B 4300 G6Standard

Adhe

sion

[N

/mm

]

Fig. 5: Adhesion to TPU by standard PBT in comparison to Ultradur®

High Speed having hardness values of 65 Shore A and 85 Shore A

The properties of Ultradur®

Molex connector

13

Table 1: The Ultradur® product range at a glance

Unreinforced

Injection grades Extrusion grades

B 2550 easy-flow properties B 2550 low-viscosity grade

B 4500 FDA compliant B 4500 medium-viscosity extrusion grade

B 4520 standard grade, easy demolding B 4520 B 6550 L B 6550 LN

high-viscosity extrusion grade high-viscosity extrusion grade with optimized feeding behavior

Glass-fibre reinforced

Standard grade (PBT - GF )

B 4300 G2-G10 (10 - 50 % GF ) Balance between stiffness and toughness, easy to process

Low-warpage grades (PBT+ ASA - GF )

S 4090 G2-G6 (10 - 30 % GF ) GX-G6X (14 - 30 % GF)

PBT+ ASA blend with very low warpage, very good flow properties and low density

Grades for good surface finishes (PBT+ PET - GF )

B 4040 G4-G10 (20 - 50 % GF ) PBT+ PET blend for applications in which good surface appearance is essential

Flame-retardant grades (PBT - GF - FR)

B 4406 G4 / G6 (20 / 30 % GF ) Standard halogenated flame-retardant grade (UL 94 V-0 at 0.75 mm); low warpage

B 4400 G5 (25 % GF) Flame-retardant grade (UL 94 V-0 at 1.5 mm) with very high CTR; contains no halogen compounds, antimony or elementary phosphorus

Specialties

Impact modified products

B 4520 Z2 Unreinforced injection-molding grade with high impact strength, even at low temperatures

B 4030 G6 (30 % GF ) Glass-fiber reinforced injection-molding grade with high impact strength enhanced resistance to hydrolysis

Mineral reinforced grades

B 4300 M5 (25 % Mineral) Mineral reinforced grades with low warpage; produces good surface finish

B 4300 GM 42 (20 % GF, 10 % Mineral ) Mineral- and glass-fiber reinforced grade with low warpage; produces good surface finish

B 4300 M2 (10 % Mineral ) Mineral reinforced grade with low warpage and high impact strength, even at low temperatures

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Instrument panel

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Fig. 8: Shear modulus and logarithmic decrement of unreinforced

Ultradur® as a function of temperature ( in accordance with ISO 6721-2 )

Fig. 7: Modulus of elasticity and elongation

The pronounced maximum in the logarithmic decrement at + 50 °C

identifies the softening range of the amorphous fractions while the

crystalline fractions soften only above + 220 °C and thus ensure

dimensional stability and strength over a wide range of temperature.

The good strength characteristics of the unreinforced and glass-fibre

reinforced Ultradur® grades permit high mechanical loads even at

elevated temperatures (Figs. 10 -12).

The behavior under short, uniaxial tensile loads is demonstrated by

stress-strain diagrams. Figure 13 shows the stress-strain diagram for

unreinforced Ultradur® B 4520 and Figure 14 shows that for glass-fibre

reinforced grades as a function of temperature. In the latter diagram

the effect of the increasing glass fibre content is apparent.

5

0.5

1

-50 0 100 150 200-100

10

50100

500

1000

500010000

0 0

0.5

1.0

B 4520

log. decrement �

Shear modulus G

Temperature [°C]

Shea

r m

odul

us [

MPa

]

Loga

rith

mic

dec

rem

ent

[�]

50

Modulus of elasticity [MPa]

4,500 7,100 10,000 12,000

B 4040 G10B 4300 G10

S 4090 G2B 4300 G2B 4040 G2

S 4090 G4B 4300 G4B 4040 G4

S 4090 G6B 4300 G6B 4040 G6

6

5

4

3

2

1

0

Elon

gati

on [

%]

7

2,500

>50B 4520

The properties of Ultradur®

Mechanical properties

The Ultradur® product range includes grades with the most varied

mechanical properties such as rigidity, strength and impact-resistance.

Unreinforced Ultradur® is distinguished by a balanced combination of

rigidity and strength with good impact-resistance, thermostability and

sliding friction properties and excellent dimensional stability.

The strength and rigidity of glass-fibre reinforced Ultradur® grades are

substantially higher than those of the unreinforced Ultradur® grades.

Figure 7 shows the dependence of the modulus of elasticity on the

glass fiber content.

The shear modulus and damping values (Figs. 8 and 9) measured in

torsion pendulum tests in accordance with ISO 6721-2 as a function of

temperature provide useful insight into the temperature-dependence of

the properties of the unreinforced and reinforced Ultradur® grades.

15

-50 100 150 200-100

10

50 100

500

1000

5000

0 0

0.5

1.0

Temperature [°C]

B 4300 G4 S 4090 G4

B 4300 G4 S 4090 G4

Shear modulus G

Shea

r m

odul

us [

MPa

]

Loga

rith

mic

dec

rem

ent

[�]

log. decrement �

500

Fig. 9: Shear modulus and logarithmic decrement of glass-fiber

reinforced Ultradur ® as a function of temperature ( in accordance

with ISO 6721-2)

Tens

ile s

tren

gth

[MPa

]

Temperature [°C]

20

00 50-40

40

200

23 150-20

60

80

100

120

140

160

180

100

B 4300 G6B 4300 G4B 4300 G2

Fig. 11: Tensile strength of glass-fiber reinforced Ultradur® B as a

function of temperature (in accordance with ISO 527, take-off speed

5 mm /min)

Yiel

d st

ress

[M

Pa]

Temperature [°C]

20

0 -40

40

60

80

100

120

23 100-20 0 50

B 4520

Fig. 10: Yield stress of unreinforced Ultradur® as a function of

temperature (in accordance with ISO 527, take-off speed: 50 mm /min)

S 4090 G6S 4090 G4S 4090 G2

Tens

ile s

tren

gth

[MPa

]

Temperature [°C]

20

0-40

40

200

150-20

60

80

100

120

140

160

180

1000 5023

Fig. 12: Tensile strength of glass-fiber reinforced Ultradur® S as a

function of temperature (in accordance with ISO 527, take-off speed

5 mm /min)

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Toughness, impact strength and low-temperature impact resistanceImpact strength may simply be specified, for example from the stress-

strain diagram, as the deformation energy at failure (see Figs. 13

and 14).

A further criterion for toughness is the impact resistance of unnotched

test rods in accordance with ISO 179/1eU. According to Table 2 the

impact resistance of unreinforced Ultradur® B4520 is higher than that

of glass-fibre reinforced Ultradur® grades.

Comparative values closer to practical conditions for the impact prop-

erties of the materials under impact loads can be measured by impact

tests or falling weight tests in accordance with DIN 53443. Based

on this standard the 50 % impact-failure energy ( E 50), i. e. the falling

energy at which 50 % of the parts are damaged, was determined for

test boxes having a wall thickness of 1.5 mm (see Table 2 ). The failure

energy is dependent on the dimensions, the thickness of the walls, the

reinforcement of the moldings and on the processing conditions.

If the highest possible notched or low-temperature impact strengths

are required impact-modified grades must be employed. In this case the

best low-temperature toughness is achieved by Ultradur® B 4520 Z2.

Behavior under long-term static loadingThe loading of a material under a static load for relatively long periods

is marked by a constant stress or strain. The tensile creep test in

accordance with DIN 53444 and the stress relaxation test in accor-

dance with DIN 53441 provide information about extension, mechani-

cal strength and stress relaxation behavior under sustained loading.

The results are illustrated as creep modulus plots, creep curves and

isochronous stress-strain curves (Figs. 15 and 16 ). The graphs repro-

duced here are just a selection from our extensive plastics databases

which we will be happy to place at your disposal on request.

Table 2: Dependence of impact strength (ISO 179 /1eU) and impact failure energy (E 50) (DIN 53443) on the glass fiber content

Property Unit B 4520 B 4300 G2 B 4300 G4 B 4300 G6 B 4300 G10

Glass content Wt.-% 0 10 20 30 50

Impact-failure energy (E 50) J > 140 12 5 1.6 0.8

Impact strength + 23 °C kJ / m2 290 40 58 67 55

20

100

10

40

60

80

80 2 6

-40°C

-20°C0°C23°C30°C

160°C

40°C

50°C60°C 80°C

100°C

120°C 140°C

B 4520

Elongation [%]

Tens

ile s

tres

s [M

Pa]

4

Fig. 13: Stress-strain diagrams for unreinforced Ultradur® at different

temperatures (in accordance with ISO 527, take-off speed 50 mm /min)

The properties of Ultradur®

17

20

0 2 4 86 10 0 2 4 86 10 0 2 4 86 10

40

60

80

100

120

140

160

180

200B 4300 G2

-40°C-20°C

0°C

23°C

40°C60°C

80°C100°C120°C

140°C140°C

120°C100°C80°C60°C

40°C

23°C

0°C

-20°C

-40°C

100°C120°C140°C

60°C

80°C

40°C

23°C

-20°C

0°C

-40°CB 4300 G4 B 4300 G6

Stre

ss [

MPa

]

Elongation [%]

Fig. 14: Stress-strain diagrams for glass-fiber reinforced Ultradur® at different temperatures ( in accordance with ISO 527, take-off speed 5 mm /min)

10 15

10

20

30

40

NK 23/50

1 h 60 °C

100 °C

1000 h 100 h 10 h

1 h

1000 h100 h10 h

10 h

1000 h10000 h

1 h

100 h

0 5

Tens

ile s

tres

s [M

Pa]

Elongation [%]

Fig. 15: Isochronous stress-strain curves for Ultradur® B 4520 under normal conditions in accordance with DIN 50014-23/50-2 and

at 60 °C and 100 °C ( DIN 53444)

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Behavior under cyclic loads, flexural fatigue strengthEngineering parts are frequently subjected to stress by dynamic forces,

especially alternating or cyclic loads, which act periodically in the same

manner on the structural part. The behavior of a material under such

loads is determined in long-term flexural fatigue tests or in rotating

bend ing fatigue tests (DIN 53442) up to very high load-cycle rates.

The results are presented in Wöhler diagrams obtained by plotting the

applied stress against the load-cycle rate achieved in each case (see

Fig. 17 ). The flexural fatigue strength is defined as the stress level a

sample can withstand for at least 10 million cycles.

It can be gathered from the illustration that in the case of Ultradur® the

stress remains practically constant above about 107 load cycles.

When applying the test results in practice it has to be taken into

account that at high load alternation frequencies the workpieces may

heat up considerably due to internal friction. In such cases, just as at

higher operating temperatures, lower flexural fatigue strength values

have to be expected.

NK 23/50

1000 h 100 h

1 h 10 h

100 h1 h 1000 h10 h

100 h 1h 10 h 1000 h

140°C

60°C

100°C

100 h 1 h 10 h

1000 h

10000 h

2 2 3131

100

80

60

40

20

0

100

80

60

40

20

0

100

80

60

40

20

0

100

80

60

40

20

0

Tens

ile s

tres

s [M

Pa]

Elongation [%]

Fig. 16: Isochronous stress-strain curves for Ultradur® B 4300 G6 under normal conditions in accordance with DIN 50014-23/50-2 and at 60 °C,

100 °C and 140 °C in accordance with DIN 53442 (60 °C /6 % r. h.; 100 °C und 140 °C < 1 % r. h.)

20

0

40

60

80

100

120

104 105 106 107 108

WBUB

Stre

ss a

mpl

itud

e [M

Pa]

Load-cycle rate

Dimensions in mmTest shape UB Test shape WB

UB Load-cycle frequency: 1500 rpmWB Load-cycle frequency: 900 Hz

10

18

8

1640

15

30306

10

30

Fig. 17: Flexural fatigue strength of Ultradur® B 4300 G6 under normal

conditions as defined by DIN 50014-23 / 50-2 in accordance with

DIN 53442, injection-molded test specimen

The properties of Ultradur®

19

Tribological properties

Ultradur® is suitable as a material for sliding elements due to its excel-

lent sliding properties and very high resistance to wear.

Sliding properties are very highly dependent on the system as a result

of which reliable prediction of the behavior of the paired material is dif-

ficult. Figures 18 and 19 show examples of friction values and wear

rates for unreinforced and glass-fiber reinforced Ultradur® on a special

tribological system having two different depths of roughness.

The coefficient of sliding friction and the wear rate due to sliding fric-

tion depend on the contact pressure, the temperature of the sliding

surfaces and the sliding distance covered. The surface roughness and

the hardness of the paired material is decisive. The sliding speed has

no appreciable effect if heating and modification of the sliding surfaces

are avoided.

0.10

00.00

0.20

0.30

0.40

0.50

0.70

1210

0.60

1 11

S 4090 G6

S 4090 G4

B 4300 G6

B 4520

Coef

ficie

nt o

f sl

idin

g fr

icti

on [

µ]

Wear rate due to sliding friction WI/s [µm/km]

2 3 4 5 76 98

Fig. 18: Coefficient of sliding friction and wear rates of unlubricated

Ultradur® at 0.15 µm depth of roughness; tribological system:

pin-on-disk; base material: disk of 100 Cr 6/800 HV steel; opposing

material: plastic; ambient temperature: 23 °C; contact pressure:

1 MPa; sliding speed: 0.5 m /s

0.10

0.00

0.20

0.30

0.40

0.50

0.70

0.60B 4300 G6

B 4520

S 4090 G6

S 4090 G4 Coe

ffici

ent

of s

lidin

g fr

icti

on [

µ]

Wear rate due to sliding friction WI/s [µm/km]

0 12101 112 3 4 5 76 98

Fig. 19: Coefficient of sliding friction and wear rates of unlubricated

Ultradur® at 3 µm depth of roughness; tribological system: pin-on-disk;

base material: disk of 100 Cr 6/800 HV steel; opposing material:

plastic; ambient temperature: 23 °C; contact pressure: 1 MPa;

sliding speed: 0.5 m /s

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Mirror actuator housing

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Thermal properties

As a partially crystalline plastic, Ultradur® has a narrow melting range

between 220 °C and 225 °C. The high crystalline component makes it

possible for stress-free Ultradur® moldings to be heated for short periods

to just below the melting temperature without undergoing deformation or

degradation.

Ultradur® is distinguished by a low coefficient of linear expansion. The

reinforced grades in particular exhibit high dimensional stability when

temperature changes occur. In the case of the glass-fiber reinforced

grades, however, the linear expansion is determined by the orientation

of the fibers.

The presence of glass fibers reinforcement the dimensional stability on

exposure to heat ( ISO 75 ) increases significantly by comparison with

unreinforced grades.

Behavior on brief exposure to heatApart from the product-specific thermal properties the behavior of

Ultradur® components on exposure to heat also depends on the

duration and mode of application of heat and on the loading. The

shape of the parts is also important. Accordingly, the dimensional

stability of Ultradur® parts cannot be estimated simply on the basis

of the temperature values from the various standardized tests.

The shear modulus and damping values measured as a function of

temperature in torsion pendulum tests in accordance with ISO6721-2

afford valuable insight into the temperature behavior. A comparison of

shear modulus curves (see Figs. 8, 9 and 14) gives provides informa-

tion about the different thermomechanical effects at low deformation

stresses and speeds. Based on practical experience the therm in the

torsion tests in which the start of softening becomes apparent.

Heat aging resistanceThermal aging is the continuous, irreversible change (degradation) of

properties under the action of elevated temperatures.

The determination of the aging characteristics of finished parts under

operational conditions is often difficult to carry out because of the long

service life required.

The test methods developed for thermal aging using standardized test

specimens make use of the increasing reaction rate of chemical pro-

cesses at higher temperatures. This dependence of service life on

temperature described mathematically by the Arrhenius equation is the

basis of the international standards IEC 216, ISO 2578 and the US

standard UL 746B.

The temperature index ( TI ) is defined as the temperature in °C at which

the permitted limiting value (usually decline of the property to 50 % of

the initial value) is reached after a defined time usually 20,000 hours.

The temperature index is available for many products and various

properties (e. g. tensile strength). The temperature indices are given in

the Ultradur® product range. If required we can provide the data and

also the associated calculation program on data media.

In Figure 20 the tensile strength of Ultradur® B 4300 G6 is plotted as

a function of storage time and storage temperature. From the graph a

temperature-time limit in accordance with IEC 216 of approx. 140 °C

after 20,000 hours can be extrapolated on the basis of a 50 % decline

in tensile strength.

Ultradur® moldings become only slightly discolored on long exposure

to thermal stress in the aforementioned temperature-time limits. In

the case of uncolored Ultradur® B 4520 for example, only a very slight

change in color can be observed after exposure to a temperature of

110 °C for 150 days. Even after storage for 100 days at 140 °C dis-

coloration due to oxidation is slight, i. e. the material is suitable for

inspection windows exposed to high temperatures, e. g. in the domestic

appliance sector.

Moving platen (wiper engine housing)

The properties of Ultradur®

21

Temperature [°C]

103

105

140

104

135 150145 160155 170165 180175

B 4300 G6

Tim

e [h

]

Fig. 20: Thermal endurance graph for glass-fiber reinforced Ultradur®

( IEC 216-1)

Electrical properties

Ultradur® is of great importance in electrical engineering and electron-

ics. It is used in insulating parts, such as plug boards, contact strips

and plug connections for example, due to its balanced range of prop-

erties. These include good insulation properties (contact and surface

resistance) in association with high dielectric strength and good track-

ing current resistance together with satisfactory behavior on exposure

to heat, in aging, and the possibility of meeting the requirements for

increased fire safety by incorporation of fire protection additives. Elec-

trical test values are compiled in the Ultradur® product range.

Figure 21 shows the dielectric constant and the dissipation factor as

a function of frequency with reference to the example of Ultradur® S

4090 G4. The electrical properties are not affected by the moisture

content of the air.

1010

3.0

5.0 0.03

0.01

4.0 0.02

S 4090 G4

102 103 104 105 106 107 108 109

�r

tan �

Die

lect

ric

cons

tant

�r

Frequency [Hz]

Dis

sipa

tion

fac

tor

�

Fig. 21: Dielectric constant and dissipation factor for glass-fiber

reinforced Ultradur® as a function of frequency

Fire behavior

General notesAbove 290 °C Ultradur® grades slowly begin to decompose. In doing

so flammable gases are given off which continue to burn after igni-

tion. These processes are affected by many factors so that, as with

all flammable solid materials, no definite flash point can be specified.

The decomposition products from charring and combustion are mainly

carbon dioxide and water and depending on the supply of oxygen

small amounts of carbon monoxide, tetrahydrofuran, terephthalic acid,

acetaldehyde and soot. The decomposition products formed in the

temperature range up to 400 °C have been shown in toxicological

investigations to be less toxic than those produced under the same

conditions from wood. At higher temperatures they are equally toxic.

The calorific value Hu according to DIN 51900 is about 31,000 kJ/kg

(unreinforced grades).

Airbag connector Motor circuit breakers

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TestsVarious material tests are carried out to assess the fire behavior of

electrical insulating materials.

The classification of the Ultradur® grades by the insulating material

test DIN IEC 707/ VDE 0304, Part 3 “Determination of flammability on

exposure to ignition sources” contains three test methods which can

be optionally used:

• BH method: ignition rod, horizontal arrangement of test specimen;

• FH method: Bunsen burner, horizontal arrangement of test specimen;

• FV method: Bunsen burner, vertical arrangement of test specimen.

A further test on rod-shaped specimens in the rating according to the

UL 94 standard, “Tests for Flammability of Plastics Materials for Parts

in Devices and Appliances” of the Underwriters Laboratories Inc. / USA.

The Ultradur® grades with halogen-containing fire-retardant additives

achieve the UL 94 rating of V-0 up to thicknesses of 0.8 mm (1/32”).

Ultradur® B 4400 G5 contains a flame retardant that is totally free of

halogens, antimony and elementary phosphorus, and achie ves a UL 94

flammability rating of V-0 at 1.6 mm (1/16). Apart from this Ultradur®

B 4400 G5 achieves the highest rating concerning tracking resistance

(UL 94) class 0.

The glow wire test according to IEL 695, Part 2 -1 is carried out on

vertically arranged boards. The ignition source is an electrically heated

wire loop which presses against the surface of the board. Flame are

spread and the formation of burning drops assessed. The glowing wire

test is becoming increasingly important for electrical engineering com-

ponents. The ratings of the Ultradur® grades are listed in Table 3.

In motor vehicle construction DIN 75200 is used as the test method for determining the flammability of materials in the interior of vehicles. Plate-like specimens arranged horizontally are tested with a Bunsen burner flame, a method which is largely equivalent to FMVSS 302 ( USA). As can be seen in the product range overviews all Ultradur® grades meet the requirements (burning rate < 100 mm /min.) set for plates up to a thickness of 1 mm.

The test on building materials for the construction industry is carried out in accordance with the supplementary provisions of DIN 4102 “Fire behavior of building materials and building parts”. Plates made from the unreinforced and glass-fiber reinforced Ultradur® grades are rated as normally flammable building materials (designation in accordance with the building regulations in the Federal Republic of Germany) in Building Materials Class B 2. The test results are summarized in Table 3.

Table 3: Fire behavior

Ultradur® DIN IEC 707/ VDE 0304 T3 Method BH FH FV

DIN 53459 ISO 181

UL 94 1/ 16” 1/ 32”

Glow wire (OC) (3 mm wall thickness) DIN IEC 695 Teil 2-1/ VDE 0471 Teil 2-1

DIN 75200 / FMV SS 302 Flame spread [mm /min]

VDE0470 § 26

B 4520 Z2 – HB / – < 100

B 4500 FH 3 – 20 mm /min II c HB / HB + 1 +

B 4520 FH 3 – 20 mm /min II c HB / HB 850 + +

B 4300 G2 – G10 BH 2 – 50 mm; FH 3 – 15 mm /min

II c HB / HB < 750 < 100 +

S 4090 G4 – G6 HB 760 < 100 +

B 4300 K4 – K6 FV2 II b HB / – < 750 < 100 +

B 4406 G4 – G6 2 FV0 II b V-0 / V-0 960 + +

B 4400 G5 3 – – V-0 / V-2 960 + +1 + means requirement fulfilled, flame extinguishes before the first mark 2 with halogen-containing flame retardants 3 with halogen-free flame retardants

The properties of Ultradur®

Tissue paper

Test rig

SpecimenWire loop(max. 960 °C)

1N

Fig. 22: Incadescent wire test

Resistance to chemicals

Ultradur® is highly resistant to many common solvents, such as alcohols,

ethers, esters, higher aliphatic esters and aliphatic perhalogenated

hydrocarbons, and to fats and oils, such as propellants, brake fluid and

transformer oils. The action of solvents and chemicals is described at

length in our Technical Information leaflet “Resistance of Ultramid®,

Ultraform® and Ultradur® to chemicals”.

Solvents having an effect at room temperature are unknown. At elevated

temperatures Ultradur® is dissolved by mixtures of o-dichlorobenzene

and phenol or tetrachloroethane and phenol as well as by o-chloro-

phenol and dichloroacetic acid. At room temperature Ultradur® is stable

to water and aqueous solutions of most salts. It exhibits limited resis-

tance to dilute acids and is not resistant to aqueous alkalis.

Polyesters are susceptible to hydrolysis, hence prolonged use of

Ultradur® in water or in aqueous solutions above 60 °C must be avoid-

ed. Brief contact with warm or hot water is not a problem. Ultradur®

B 4030G6 is available as a special grade for cases where improved

resistance to hydrolysis is a particular requirement.

Stress cracking of Ultradur® due to solvents or other chemicals has so

far not been observed. Clearance for the use of the material for highly

stressed components in potentially aggressive chemicals requires that

its chemical suitability be reliably demonstrated. This may be done on

the basis of experience with similar parts made of the same material in

the same medium under similar conditions or by testing the part under

conditions in practice.

Door handle

23

Behavior on exposure to weather

As has been shown by 3-year exposure to weather in the open in Cen-

tral Europe, moldings made from Ultradur® tend to discolor only very

slightly and their surface scarcely changes. Mechanical properties too,

such as rigidity, tensile strength and tear strength, are hardly adversely

affected. After a weathering test for 3,600 hours in the Xenotest 1200

device the values for tensile strength still amount to 90 % of the ini-

tial value. On the other hand elongation at break is more adversely

affected. Using Xenotest 1200 equipment, BASF simulated e. g. 5 - 6

years of weathering in the open air. Parts for outdoor use should be

manufactured from black-colored material in order to prevent impair-

ment of strength due to surface attack. Fibre-reinforced grades such

as Ultradur® B 4040 G2 /G4/G6 /G10 with outstanding surface quality

and high resistance to UV radiation are suitable for parts subject to

particularly extreme exposure. These grades have outstanding surface

quality and exhibit high resistance to UV radiation.

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Ultradur® should generally have a moisture content of less than 0.04 %

when being processed.

In order to ensure reliable production, therefore, pre-drying should

generally be the rule and the machine should be loaded via a closed

conveyor system. Appropriate equipment is commercially available.

Pre-drying is also recommended for the addition of batches, e. g. in the

case of inhouse pigmentation.

In order to prevent the formation of condensed water, containers stored

in unheated rooms must only be opened when they have attained the

temperature prevailing in the processing area. This can possibly take a

very long time. Measurements have shown that the interior of a 25-kg

bag originally at 5 °C had reached the temperature of 20 °C in the pro-

cessing area only after 48 hours.

As a general rule Ultradur® can be processed by all

methods known for thermoplastics. The main meth-

ods which come into consideration, however, are

injection molding and extrusion. Complex moldings

are economically manufactured in large numbers

from Ultradur® by injection molding. The extrusion

General notes

Moisture and dryingThermoplastic polyesters, such as polybutylene terephthalate (PBT) for

example, are susceptible to hydrolysis. If the moisture content during

fusion in the course of processing is too high, degradation will occur.

This results in cleavage of the molecular chains and hence in a reduc-

tion in the mean molecular weight.

In practice this manifests itself in a loss in impact resistance and

elasticity. The decline in strength usually turns out to be less marked.

Degradation of the material can be demonstrated by determining the

viscosity number according to DIN ISO 1628-5 or the melt volume

index according to ISO 1133.

Particular care therefore has to be devoted to pretreatment of the

pellets and processing in order that high quality of the finished parts

and low fluctuation in quality can be guaranteed.

The processing of Ultradur®

process is used to produce film, semi-finished prod-

ucts, pipes, profiled parts, sheet and mono filaments.

Semi-finished products are for the most part ma-

chined further by means of cutting tools to form fin-

ished moldings. The Ultradur® S types are especially

suitable for the Mucell® process (frothing).

Process simulation: Calculation of the load on inserts during the charging process

Housing with conductor strips and retaining pins

Flow pattern

Load calculationCharging simulation

25

Of the various dryer systems possible, the dry air dryer has proved to

be technically and economically superior.

Drying times for these devices amount to 4 hours at 80 °C to 120 °C.

In general the directions of the equipment manufacturer should be

observed in order to achieve the desired drying effect. The use of

vented screws is inadvisable.

Production stoppages and change of materialDuring brief production stoppages the screw should be advanced to

the forwardmost position and when downtimes are relatively long the

barrel temperature should be additionally lowered. Before restarting

after stoppages thorough purging is required.

When there is a change of material the screw and barrel must be

cleaned in advance. HDPE of high molecular weight as well as glass-

fiber reinforced HDPE and GFPP have proved to have good cleaning

action in such cases.

loose buffer tubes for optical fibers

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ReprocessingReprocessing of reground parts and sprue is usually possible. Since,

however, degradation to a greater or lesser degree can occur in each

processing cycle checks should first of all be made as to how exten-

sive this is in the case in question. Checks on the viscosity number in

solution or the melt viscosity provide useful information.

If the material was handled gently in the first pass then as a rule up to

25 % of the regranulated material can be mixed with the fresh granules

without any appreciable decline in the characteristics of the material.

In the case of flame retardant products limits to the quantity of regrind

permitted have to be observed (e. g. by means of UL specifications).

When regrind is added care has to be taken that there is adequate

predrying (see section on “Moisture and drying”).

Loading Deformation and stress

Structure simulation

26

Self-coloringFurther shades other than those in our product range can be made up

by means of self-coloring using masterbatches. When choosing the

masterbatch attention should be paid to a high level of compatibility

with Ultradur® so that its range of properties is not affected. We recom-

mend PBT-based color batches.

In the case of flame-retardant products care must be taken that

only masterbatches are used which do not change its rating (e. g.

according to UL).

Our Ultraplaste-Infopoint will be happy to provide you with the addresses

of suppliers of suitable masterbatches.

D hEhAR S

LLA LK LE

DLLL

D

18-230.5-0.550.25-0.3

0.2

0.8-1.0

outer diameter of the screweffective screw lengthlength of feed sectionlength of compression section length of metering sectionflight depth in the metering sectionflight depth in the feed sectionpitchnon-return valve

DLLE

LKLAhAhE

SR

Fig: 24: Screw geometry – terms and dimensions for three-section

screws for injection-molding machines

Fig: 25: Screw geometry and screw flight depths for three-section

screws in injection-molding machines

Storage time [min]

Moi

stur

e co

nten

t [W

t.-%

]

B 4520

00.00

0.10

100 200 300

0.06

0.05

0.04

0.03

0.02

0.01

400 500 600

0.07

0.08

0.09

24°C/59 % rel. humidity24°C/94 % rel. humidity

Fig. 23: Absorption of moisture by unreinforced Ultradur® as a

function of time

30 40 60 80 90 130

2

4

6

12

50 70 100

10

8

110 120

hE

hA

Flig

ht d

epth

h [

mm

]

hE = flight depth in the feed sectionhA = flight depth in the metering section

standard screwshallow screw

Screw diameter-Ø D [mm]

The processing of Ultradur®

Plug-in connector

Injection molding

Injection unitWhat is known as the “normal screw” is suitable for processing

Ultradur®. A single-flighted, shallow-cut three-section screw having

a L / D ratio of 18 - 22 D is better for PBT. For the same screw diameter

shallow flighted screws ensure a shorter residence time of the melt

in the cylinder and a more homogeneous temperature distribution in

the melt.

When processing GF-reinforced PBT grades hard-wearing steels

should be used for the cylinder, screw and non-return valve. At higher

holding pressures the non-return must also prevent backflow of the

melt out of the space in front of the screw so that sink marks or voids

in the part are reliably avoided. The need for a check on the adequacy

of sealing or excess play is always indicated when the melt cushion in

the filled mold reduces markedly in the holding phase.

Due to the viscous melt Ultradur® can be processed both with an

open nozzle as well as with a shut-off nozzle. The use of nozzle

heater bands is recommended.

Mold designFor Ultradur® both conventional cold runners as well as hot runner

systems can be used.

Diversions have to be designed in a manner favoring flow in order to

avoid deposits. Here furthermore, good thermal isolation at the gate

is important. In this way the temperatures of the heated and cooled

regions can be more directly controlled and the total energy require-

ments for heating and cooling are reduced.

The most suitable type of gate depends on the specific application and

must therefore be selected for each case.

At mold temperatures above 60 °C the installation of thermal insulation

panels between the machine platen and the mold base plate should

be considered. As a result less heat energy is lost and the temperature

distribution in the mold is more uniform.

Temperature control in the mold should be so effective that even over

long production periods the desired temperatures are attained in all

contour-forming regions or selective temperature changes can be

produced at particular points by means of independent temperature

control circuits. The quality of an effective cooling system is shown in

that temperature fluctuations during the cycle phase are as small as

possible. Draft angels of 1° per side allow problem-free demolding.

27

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Processing temperature and residence timeThe recommended range of melt temperatures for the various Ultradur®

grades is 250 °C to 270 °C. In order to work out the optimum machine

setting experience suggests that a start should be made at the tem-

perature of 260 °C.

The choice of melt temperature depends on the flow lengths and wall

thickness and on the residence time of the melt in the cylinder.

Unnecessarily high melt temperatures and excessively long residence

times of the melt in the cylinder can bring about molecular degrada-

tion. Figure 28 shows an example illustrating how the viscosity number

acts as a measure of the molecular weight as a function of the melt

temperature and residence time.

Based on experience material degradation of less than 10 % based on

the measured viscosity in solution of the granules and the molding is

tolerable. In the event of values higher than this the processing param-

eters and pretreatment should be checked.

Metering and back pressureWhen metering in, the peripheral screw speed and the level of back

pressure have to be limited with a view to gentle handling of the

material.

Gentle infeed is guaranteed for peripheral screw speeds of up to

15 m /min. Figure 26 shows the speeds to be set as a function of the

screw diameter.

On the basis of experience the back pressure, which should ensure

improved homogeneity of the melt and is therefore desirable, should,

however, be limited to 10 bar due to the risk of excessive shear.

Good feed behavior is best achieved by means of rising temperature

control. This is illustrated by way of example in Figure 27.

10

15

20

35

30

25

5

40

45

50

55

60

050 200100 150 250 3000

60

45

30

15

20

Peri

pher

al s

peed

[m

/min

]

Maximumrecommended

speed15 m/min

Screw diameter-Ø D (mm)

Rotary speed [rpm]

Fig: 26: Peripheral screw speed as a function of rotary speed and

screw diameter

4

260 260 260 260 260 260 60 °C

260 255 250 245 240 235 60 °C

Heaters

Temperature control

steady

rising

Hopper15 6 23

Fig. 27: Cylinder temperature control for Ultradur®

The processing of Ultradur®

29

Mold surface temperatureOn the basis of experience mold surface temperatures should lie in the

range of 40 °C to 80 °C for unreinforced materials and 60 °C to 100 °C

for reinforced materials. These temperatures can usefully be attained

using water systems.

In the case of components with high demands on surface quality, espe-

cially in the case of glass-fibre reinforced grades, care should be taken

that the mold surface temperature is at least 80 °C or higher.

Since the mold temperature has an effect on shrinkage, warpage and

surface quality it is of great importance for the dimensional accuracy

of parts.

The trend of the effect of mold surface temperature on shrinkage

behavior is illustrated in Figures 32 to 35 with reference to the exam-

ples of Ultradur® B 4520 and B 4300 G6. Ultradur® S 4090 G2-G6

represent grades having especially low warpage.

500

450

400

250

200

150

100

50

350

300

0

B 4300 G2 B 4300 G4 S 4090 G6B 4300 G6 S 4090 G4

Spir

al le

ngth

[m

m]

Melt temperature 260 °C Melt temperature 280 °C

Fig. 29: Flow behavior of glass-fiber reinforced Ultradur® grades;

spiral length as a function of melt temperature; wall thickness 1.5 mm

70

060

5

80

90

100

110

130

20 3510 15 25

120

30

240°C

250°C

260°C

270°C

280°C290°C300°C

B 4520

Visc

osit

y nu

mbe

r [m

l/g]

Residence time in the plasticating unit [min]

Fig. 28: Polymer degradation (as measured by the drop in viscosity

number) in Ultradur® test specimens as a function of the melt

temperature and residence time in the plastication unit

Flow behavior and injection speedIn general the plastic melt should be injected into the injection-mold

as rapidly as possible. However, in the case of particular component

geometries and gate types it may be necessary to reduce the injection

rate.

The flow behavior of the melt is of great importance for the charging of

the mold. It can be assessed using spiral molds on commercial injec-

tion molding machines. The path covered in this mold is a measure of

the flow properties.

In Figure 29 the spiral lengths for some selected Ultradur® grades are

presented.

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Injection pressureThe required injection pressure very much depends on the flow proper-

ties of the material, the type of gate and the geometry of the molding.

Figure 30 depicts the test box used by way of example for carrying out

injection pressure tests. Figure 31 shows plots of injection pressure for

some selected Ultradur® grades as a function of the melt temperature.

ShrinkageDIN 16901 defines the terms and test methods for shrinkage in pro-

cessing. According to this shrinkage is defined as the difference in the

dimensions of the mold and those of the injection-molded part at room

temperature. Shrinkage is primarily a property of the material but it is

also determined by the geometry (free or impeded shrinkage) and the

wall thickness of the injection molding.

In addition the position and size of the gate and the processing param-

eters (melt and mold temperature, pressure and holding time) together

with the storage time and storage temperature play a decisive role. The

interaction of these various factors makes exact prediction of shrinkage

very difficult.

A ≈ B ≈ C ≈ D ≈ E ≈

107 mm47 mm40 mm60 mm

120 mm

A

B

E

D

C

Fig. 30: Test box

500

1000

250 270260

1

234

5

6

1 = B 4300 G102 = B 4300 G63 = B 4300 K4, K6 4 = B 4300 G45 = B 4300 G26 = B 4520 Z2

Melt temperature [°C]

Inje

ctio

n pr

essu

re [

bar]

Fig. 31: Flowability as a function of melt temperature.

Machine: 800 kN, cycle time = 20 s, screw diameter = 30 mm,

mold surface temperature = 80 °C, injection speed = 16 mm /s

In the Ultradur® product range guide values for shrinkage are given.

These guide values were determined for boards having a thickness

of 3 mm which were able to shrink freely. The melt temperature was

260 °C while the mold temperature was 60 °C for unreinforced and

80 °C for reinforced materials and the holding pressure was 500 bar.

The extent of shrinkage in a particular component depends on many

factors. The most important determining factors are listed below.

• The geometry of the injection-molded part (differences in wall

thickness, free or impeded shrinkage)

• The process technology used in production ( holding pressure, mold

surface temperature, melt temperature, injection rate, etc.)

• Type and arrangement of the gate ( pin, sprue or film gate)

• The orientation of the glass fibers ( parallel or transverse with respect

to the direction of flow)

• The storage period after cooling (aftershrinkage)

• The storage temperature ( tempering effect )

The processing of Ultradur®

31

20 30 40 50 60 70 9080

1.0

0.4

0.6

0.8

500

1000

1500

B 4300 G6

Shri

nkag

e [%

]

Mold surface temperature [°C]

(MT) 260 °CMelt temperature Wall thickness ≥ 3.0 mm

Wall thickness = 1.5 mm

Hol

ding

pre

ssur

e [b

ar]

Fig. 33: Shrinkage diagram for glass-fiber reinforced Ultradur®

200

0.5

30 40 50 60 70 9080

1.0

1.5

2.0

500

1000

5001500

1000

1500

B 4520

Shri

nkag

e [%

]

Mold surface temperature [°C]

(MT) 260 °CMelt temperature Wall thickness ≥ 3.0 mm

Wall thickness = 1.5 mm

Hol

ding

pre

ssur

e [b

ar]

Fig. 32: Shrinkage diagram for unreinforced Ultradur®

In order to illustrate the effect of some of these parameters the shrink-

age is presented by way of example as a function of the mold surface

temperature for wall thicknesses of 1.5 and 3 mm for unreinforced

Ultradur® B 4520 in Figure 32 and for glass-fiber reinforced Ultradur®

B 4300 G6 in Figure 33. Additionally in this investigation the holding

pressure was varied in stepwise manner from 500 through 1000 to

1500 bar. The test component was a test box as shown in Figure 30.

The specified shrinkage values were measured along the longitudinal

direction of the box.

Depending on the processing conditions, aftershrinkage of the com-

ponents can occur. Figure 34 for unreinforced Ultradur® B 4520 and

Figure 35 for glass-fiber reinforced Ultradur® B 4300 G6 give an

impression of how large aftershrinkage can be as a function of the

mold surface temperature.

After storage for 60 days at room temperature only the molded parts

produced at low mold temperatures exhibited small dimensional varia-

tions (about 0.1 %). After tempering, i. e. hot storage for 24 hours at

120 °C, the same parts exhibited marked aftershrinkage, especially

those produced at low mold temperatures. As the mold surface tem-

perature rises aftershrinkage steadily drops. This behavior should be

taken into account when designing parts for use at elevated opera-

tional temperatures.

The Ultradur® grades S 4090 G2-G6 represent alternatives having

lower shrinkage. Their shrinkage and warpage behavior are compared

with those of the Ultradur® B 4300 and B 4040 grades (20 % GF) in

Figures 36 and 37.

Headlamp bezels

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5

4321

B 4520

30 40 50 60 70 80 90 100 110 120 13020

1.0

1.5

2.0

0.5

Shri

nkag

e [%

]

Wall thickness 2 mm

1100 kNtest box2 mm

265°C660 bar107 mm

Machine:Mold:Wall thickness:

Plastic temperature:Holding pressure:Dimension measured A:

Mold surface temperature [°C]

Fig. 34: Effect of mold temperature and post-molding conditions on

the shrinkage of unreinforced Ultradur®.

1 Shrinkage measured 1 hour after injection.

2 Shrinkage measured 24 hours after injection.

3 Shrinkage measured 14 days after injection.

4 Shrinkage measured 60 days after injection.

5 Shrinkage measured after tempering ( for 24 hours at 120 °C)

30 40 50 60 70 80 90 100 110 12020

43

1/2

5

B 4300 G6

1.0

0

0.8

0.6

0.4

0.2

1.2Wall thickness 1 mm

Shri

nkag

e [%

]

1100 kNtest box1 mm

265°C660 bar107 mm

Machine:Mold:Wall thickness:

Plastic temperature:Holding pressure:Dimension measured A:

Mold surface temperature [°C]

Fig. 35: Effect of mold temperature and post-molding conditions on

the shrinkage of glass-fiber reinforced Ultradur®

Table 4: Table of corrections for shrinkage calculations [%]

Holding pressure PN Melt temperature 250 °C Melt temperature 270 °C

[bar] TMold* 40 °C TMold* 80 °C TMold* 40 °C TMold* 80 °C

500 1000 1500

+ 0.05 + 0.08 + 0.10

+ 0.08 + 0.10 + 0.15

– 0.05 – 0.08 – 0.10

– 0.08 – 0.10 – 0.15

Holding pressure PN 1.5 mm wall thickness 3.0 mm wall thickness

[bar] TMold* 40 °C TMold* 80 °C TMold* 40 °C TMold* 80 °C

500 1000 1500

+ 0.20 + 0.20 + 0.15

+ 0.30 + 0.25 + 0.20

– 0.30 – 0.25 – 0.20

– 0.40 – 0.35 – 0.25

The processing of Ultradur®

* TMold = Mold temperature

WarpageThe warpage of an injection-molded part is caused mainly by differen-

tial shrinkage in the direction of flow and in the direction transverse to

this. Warpage is often particularly noticeable in the case of glass-fiber

reinforced materials. In addition, this increases as the mold surface

temperature rises.

On the other hand shrinkage in the direction of flow and transverse

to this is approximately the same in unreinforced, mineral-filled and

33

0

B 4300 G4

B 4040 G4

B 4090 G4

0,5 1,0 1,5

1,

0,8

0.3

0.8

1.0

Warpage [mm]

0 0.5 1.0 1.5

Fig. 37: Warpage behavior of glass-fiber reinforced Ultradur®

( Test box with walls 1.5 mm thick; melt temperature = 260 °C;

mold surface temperature = 80 °C)

Shrinkage after 1 h [%]perpendicular to melt flowparallel to melt flow

0.38

0.25

0.67

0.4 1.0

0.42

1.0

0.2

B 4300 G4

B 4040 G4

S 4090 G4

0.6 0.8 1.2

1.25

Fig. 36: Shrinkage behavior of glass-fiber reinforced Ultradur®

( Test box with walls 1.5 mm thick; melt temperature = 260 °C;

mold surface temperature = 80 °C)

glass-bead filled products. Injection-moldings which due to their design

tend particularly readily to warp should therefore be manu factured as

far as possible from these Ultradur® grades or from the lower-warpage

glass-fiber reinforced Ultradur® S grades.

In many cases warpage-free moldings can be produced by differential

temperature control of the mold parts.

Steering wheel module

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Extrusion

Fundamentals, screw geometryThe following Ultradur® resins listed in order of rising viscosity are

available for extrusion:

Ultradur® B 2550

Ultradur® B 4500

Ultradur® B 6550

Ultradur® B 6550 L

Ultradur® B 6550 LN

Typical values for characteristic properties are given in Table 5.

Ultradur® B 2550 is suitable for the production of monofilaments and

bristles.

Ultradur® B 4500 is suitable for the extrusion of flat films, Ultradur® B

6550 for the extrusion of thin-walled and thick-walled tubes, hollow

and solid profiles and semi finished parts.

Ultradur® B 6550 L and B 6550 LN is also primarily intended for pro-

ducing buffer tubes used in fibre optic cables. It fulfils the requirements

imposed by today’s trend towards higher extrusion speeds and /or bet-

ter tensile properties. Ultradur® B 6550 L is additional modified with

lubricant for an better feeding performance ( for extruders with a critical

feeding behavior). Ultradur® B 6550 LN is nucleated and is recom-

mended when tubes with a higher stiffness are required.

The processing properties of the aforesaid grades are similar to those

of Polyamide 6. In general, therefore, the product can be processed on

installations suitable for polyamides.

The same is true for the screw geometry. Experience to date has

shown that all Ultradur® extrusion grades can be extruded using the

same three-section screws which have also proved to be effective in

the processing of polyamides.

For Ultradur® the compression section and the flight depth ratio are

even more important than for polyamide. Rapid build-up of a suf-

ficiently high pressure has to be ensured by choosing a screw having

a short compression section and a high flight depth ratio between the

feed and metering sections.

The length of the compression zone should, therefore, not exceed

4 - 5 D and the flight depth ratio should be approximately 3 :1. However,

good results have also been achieved using screws with short com-

pression zones.

Extruded Ultradur® B 6550 LN profile – circular, square and hollow

rods together with sheet and flat bars are principally used as semi-

finished parts for machine-cutting to produce engineering articles for

which production by injection-molding does not come into consider-

ation due to the small numbers involved.

Tubes made from Ultradur® B 6550 L and B 6550 LN are resistant

to fuels, oils and greases and for favorable sliding friction and wear

properties.

Table 5: Typical values for the characteristic properties of Ultradur® extrusion grades

Property Unit Test method B 2550 B 4500 B 6550 B 6550 L B 6550 LN

Density g/cm3 ISO 1183 1.30 ± 0.01 1.30 ± 0.01 1.30 ± 0.01

Melting temperature °C ISO 11357-3 220 - 225 220 - 225 220 - 225

Processing temperature °C – 230 - 290 230 - 290 230 - 290

Melt viscosity – – low medium high

Viscosity number cm3/g ISO 1628 o-dichlorobenzene, phenol 1:1, c = 0,5 g / 100 ml solvent

approx. 107 approx. 130 approx. 160

The processing of Ultradur®

35

The ability of Ultradur® tube to withstand compressive loads is remark-

ably high not only at normal temperatures but also at higher tempera-

tures. They can for example withstand burst pressures higher by at

least a factor of 1.5 than polyamide tubes of comparable size.

Thin-walled pipes made from Ultradur® B 6550 L and B 6550 LN

are therefore generally suitable for fuel and oil pipes, pneumatic and

hydraulic control lines, pipes for central lubrication systems, Bowden

cables and other cable systems.

Production of semi-finished products and profile sectionsUltradur® B 6550 and B 6550 LN is formed into circular, square,

square-section and hollow rods under pressure by the cooled-die

extrusion method, i. e. with cooled or temperature-controlled mold pipes.

Due to the necessarily lengthy residence time of the melt the melt

temperature has to be kept as low as possible. In the case of layers

thicker than 70 - 80 µm it should not exceed 250 °C.

In contrast with polyesters based on polyethylene terephthalate the

temperature of the cooled die in the case of Ultradur® need not be

elevated, i. e. temperature control can be effected with water at room

tem perature. If the melt temperature has to be reduced due to increas-

ing layer thickness it is, however, more favorable in respect of surface

quality and state of stress in the parts to operate with water of higher

tem perature (60 °C to 80 °C; see the processing example for the produc-

tion of round-section rod in Table 6). As with other partially crystalline

thermoplastics, suitably high pressures are also needed in the case

of Ultradur® for compensating for the volume shrinkage occurring on

solidification of the melt.

Production of sheetUltradur® B 6550 LN sheet and slab, are produced on commercial,

horizontally arranged installations having a sheet die, three-roll pol-

ishing stack and a following take-off unit. The sheet die should have

lips which extend up close to the nip. The temperature control of the

rolls depends on the sheet thickness in question and ranges from 60

to 170 °C (for processing example see Table 7 ). The throughput and

off-take rate are matched to one another in such a way that a small,

uniform bead is formed over the width of the roll ahead of the nip. The

uniformity of this bead is of great importance for the tolerances and

surface quality of the sheet.

Table 6: Rod extrusion example for Ultradur® B 6550 LN

Rod diameter 60 mm

Extruder 45 mm , 20 D

Screw – Section lengths – Flight depths

L E = 9 D, L K = 3 D, L P = 8 D h1 / h2 = 6.65/2.25 mm

Temperature settings – Adapter – Die (heated part) – Die (cooled part)

235 / 245 / 250 °C 240 °C 250 °C 20 °C

Screw speed 16 U /min

Melt pressure approx. 30 bar

Take-off speed 27 m /min

Output 5.9 kg / h

Table 7: Sheet extrusion example for Ultradur® B 6550 LN

Sheet dimensions 780 x 2 mm

Extruder 90 mm , 30 D

Screw – 3-Section lengths – Flight depths

L E = 11.5 D, L K = 4.5 D, L P = 14 D h1 / h2 = 14.0 /4.3 mm

Die 800 mm wide

Temperature settings – Hopper – Barrel – Adapter – Die

40 °C 215 / 220 / 235 / 260 / 230 / 225 / 220 / 220 °C 230 °C throughout 230 °C

Three-roll-stack 300 mm roll diameter Temperature top 50 °C center 115 °C bottom 170 °C

Screw speed 34 U /min

Melt temperature 256 °C

Take-off speed 0.76 m /min

Output 100.8 kg / h

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Production of tubesTubes made from Ultradur® B 6550 L and B 6550 LN with diameters

up to approx. 8 mm and a wall thickness of 1 mm are produced by the

vacuum water bath calibration method. Both sizing tubes and sizing

plates are suitable for calibration. In both cases the internal diameter

is chosen to be approximately 2.5 % greater than the desired outer

diameter of the tube to be produced. Based on experience this differ-

ence corresponds to the shrinkage in processing. To achieve the high-

est possible haul-off speeds with Ultradur® B6550 L and B6550LN,

the ratio of the pipe die diameter to the internal diameter of the sizing

sleeve must range from about 2 :1 to 2.5 :1. The die gap of the pipe

extrusion head should be 3 to 4 times the size of the desired wall

thickness of the tube. A processing example for the production of tube

is described in Table 8.

Production of filmFlat film made from Ultradur® B 4500 is manufactured by the usual

method using slot dies and chill rolls. With appropriate cooling the films

have very good transparency and at the same time they are rigid and

have good surface slip. A processing example is reproduced in Table 9.

Ultradur® B 4500 film of 12 - 100 µm gauge can be produced under

appropriate production conditions in thicknesses. They are highly trans-

parent and have good surface slip and high rigidity. The properties of

such films are given in Table 10. Adhesive-tape resistant vapor deposi-

tion of aluminum is readily possible on these films. The barrier proper-

ties are improved still further by the vapor deposition.

Ultradur® B 4500 monofilm or multilayer ( with PE ) can be sterilized

on their own and in composites without risk of damage using super-

heated steam at 120 °C to 140 °C, ethylene oxide or ionizing radiation

(2.5 x 104 J/kg). They are therefore also suitable as a packaging mate-

rial for sterilized goods.

The films made from Ultradur® B 4500 can be oriented uniaxially or

biaxially.

Ultradur® B 4500 monofilm can be welded by means of ultrasonics.

Joining is also possible using parting line welding based on the thermal

impulse principle. In this case, however, postcrystallization produces a

white zone in the area of the welded joint.

Production of monofilaments and bristlesMonofilaments made from Ultradur® B 2550 for the paper screening

fabric sector are produced on commercial extruders. The usual mono-

filament diameters lie in the range of 0.5 mm to 1.0 mm. To achieve

good uniformity of diameter water spinning bath temperatures of

60 °C to 80 °C are required when cooling.

In comparison with polyesters made from polyethylene terephthalate

Ultradur® exhibits better resistance to hydrolysis which can be sub-

stantially increased by using standard stabilisers based on polycarbodi-

imides.

Bristles for toothbrushes are extruded from Ultradur® B 2550. Finish-

ing treatments in the autoclave or in hot water baths for improving the

ability to return to the upright position are not absolutely necessary.

Toothbrush bristles made from Ultradur® are distinguished primarily by

low water absorption, high resistance to abrasion and excellent powers

of return to the upright position.

Examples of the production of monofilaments and bristles from

Ultradur® are presented in Table 11.

Table 8: Processing example for the production of tube from Ultradur® B 6550 L and B 6550 LN

Tube dimensions 6 x 1 mm

Extruder 45 mm , 20 D

Screw – Section length – Flight depths

L E = 9 D, L K = 3 D, L P = 8 D h1 / h2 = 6.65 / 2.25 mm

Temperature settings – Extruder – Adapter – Die

250 / 240 / 230 °C 225 °C 215 °C

Die – Die diameter – Mandrel diameter – Gap

14 mm 6.8 mm 3.6 mm

Waterbath-vacuum calibration unit – Sizing plate diameter – Water temperature

6.15 mm 19 °C

Screw speed 72 U /min

Take-off speed 20 m /min

Output 24 kg / h

The processing of Ultradur®

37

Table 11: Processing examples for the production of monofilaments and bristles from Ultradur®

Diameter Monofilaments 0.70 mm

Bristles 0.20 mm

Extruder D = 45 mm, L = 25 D

Screw three-section screw, 6 D/7 D/9 D + 3 D

Die – Die head diameter – Die head length

2.4 mm 4.8 mm

0.65 mm 0.90 mm

Temperature control – Section 1 – Section 2 – Section 3 – Section 4 – Head – Pump – Die – Melt

265 °C 275 °C 270 °C 265 °C 270 °C 270 °C 270 °C 270 °C

260 °C 265 °C 260 °C 255 °C 260 °C 260 °C 260 °C 260 °C

Water bath temperature Die spacing Cooling path length

70 °C 160 mm 900 mm

45 °C 40 mm 780 mm

– Take-off rate – Stretching temperature (hot air), 1st heater – Stretching unit 1 – Stretching temperature (hot air), 2nd heater – Stretching unit 2 – Fixing temperature, 3rd heater, 20 m /min – Fixing unit

20 m /min 155 °C 80 m /min 235 °C 110 m /min 230 °C 101.2 m /min

25 m /min 160 °C 112.5 m /min – – 200 °C 101.3 m /min

Stretching ratio 1 Stretching ratio 2 Overall stretching ratio Mechanical shrinkage

1: 4.0 1: 1.38 1: 5.5 8 %

1: 4.5 – 1: 4.5 10 %

Table 9: Film extrusion example for Ultradur® B 4500

Dimensions Gauge approx. 30 µm, width 650 mm

Screw – Section lengths – Flight depths

D = 63.5 mm, L/D = 24 L E = 7 D, L K = 5 D, L P = 12 D h1 / h2 = 8.5 / 2.5 mm

Screen pack 400, 900, 2500, 3600 mesh count /cm2

Die Width 800, die gap 0.5 mm

Heater band temperatures 230 /245 /255 / 265 °C / die 225 °C

Melt temperature 280 °C

Melt pressure 75 bar

Chill rolls – Temperature – Diameter

approx. 55 °C 450 mm

Screw speed 40 U /min

Take-off speed 26 m /min

Output 44 kg / h

Table 10: Properties of film made from Ultradur® B 4500 (gauge approx. 25 µm, measured in standard atmosphere 23 ºC / 50.r. h. after saturation)

Unit Value Test method

Mechanical properties

Yield stress S (para. & perp.)

MPa 30 - 35 ISO 527

Tear strength R (para. & perp.)

MPa 75 - 80 ISO 527

Strain at break R (para. & perp.)

% 450 - 500 ISO 527

Gas transmission – Water vapor transmission rate – Nitrogen gas transmission rate – Oxygen permeability – Carbon dioxide permeability

g/(m2 · d) ml/(m2 · d) ml/(m2 · d · bar) ml/(m2 · d · bar)

10 12 60 550

ASTM F 1249 ASTM D 3985-81

Optical properties

Haze % 1 ASTM D 1003

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Steering angle sensor

Fabrication and finishing processes

MachiningSemi-finished parts and moldings made from Ultradur® can be readily

machined with cutting tools. This includes drilling, turning on a lathe, tap-

ping, sawing, milling, filing and grinding. Special tools are not necessary.

Machining is possible using standard tools suitable for machining steel on

all standard machine tools.

As a general rule cutting speeds should be high and feed rate low with

rapid removal of shavings and chips. The cutting tools must always be

sharp. Since Ultradur® has a high softening point cooling is generally not

required. However, the working conditions must be chosen in such a way

that the temperatures do not exceed 200 °C.

Joining methodsParts made from Ultradur® can be joined at low cost by a variety of

methods. The mechanical properties of Ultradur®, especially its tough-

ness, allow the use of self-tapping screws. Ultradur® parts can be

connected without difficulty to one another or to parts made from other

materials by means of rivets and bolts. Ultradur®’s outstanding elasticity

and strength, even at high temperatures, enables economic manufac-

ture of high-performance snap- and press-fitting connectors.

Ultradur® parts can be bonded to other parts made of this or another

material using two-component adhesives based on epoxide resins,

polyurethanes, silicones or even cyanoacrylates. The highest bonding

strengths can be achieved when the surfaces to be joined together are

roughened and degreased with a solvent such as acetone.

The processing of Ultradur®

39

Known methods for welding Ultradur® include heating-element and

ultrasonic welding as well as spin and vibration welding. Apart from

being a gentle joining technique, laser welding is an attractive option

for joints that are subjected to little or no stress. Only high-frequency

welding is not feasible for this plastic on account of the low dielectric

loss factor. Due to its range of variation the ultrasonic joining technique

in particular affords the possibility of integrating the bonding of mass-

produced injection-molded parts efficiently and synchronously into fully

automated production flows. Design of the mating surfaces in line with

the welding technique together with optimum processing parameters

are the prerequisites for obtaining high-quality welded joints. It is

therefore important to consider at the design stage how parts are to be

welded and then to design the mating surfaces accordingly.

Further details can be found in the corresponding guidelines of the

DVS (Deutscher Verband für Schweißtechnik = German association

for welding technology). Ultrasound also can be used to embed metal

inserts into preformed holes.

Printing, embossing, varnishing and metallizationThe recommended binders for flexo and intaglio printing are a polyam-

ide resin or a polyamide resin in association with nitrocellulose and for

letterpress printing a standard printing varnish free of mineral oil. Two-

component printing inks are particularly suitable for screen printing.

Stoving at temperatures of 80 °C to 120 °C ensure the best results with

respect to resistance to scratching and adhesive tapes.

Printing of the highest quality on Ultradur® is obtained by heat transfer

printing using subliming disperse dyestuffs.

Very good results are also obtained with laser-printing on Ultradur®

moldings. There is an abundance of experience in this area which we

will be happy to share. Special tints for high-contrast laser-lettering

are available at our Ultraplaste-Infopoint. Our LS types are especially

suited for that method.

Ultradur® can be chrome-plated without difficulty and hot-stamped with

suitable embossing foils.

Ultradur® can be coated with various coating systems, such as hydro-

soft paints for example.

Priming and painting systems for the automotive industry are also

known which permit on-line coating of Ultradur® at temperatures of

up to 160 °C. In doing so it has to be borne in mind that in addition to

the normal molding shrinkage, further shrinkage of 0.1 - 0.2 % appears

when painted parts are stoved. The exact level of shrinkage depends

on the oven temperature.

Ultradur® parts can be metallized in high vacuum. Both vapor and sput-

ter deposition techniques produce high gloss surface finishes. Ultradur®

moldings can be colored in a dye bath using water-dispersible pigments .

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Safety notes

Safety precautions during processingUltradur® melts are thermally stable at temperatures up to 280 °C and

do not give rise to hazards due to molecular degradation or the evolu-

tion of gases and vapors. Like all thermoplastic polymers, however,

Ultradur® decomposes on exposure to excessive thermal stresses, e. g.

when it is overheated or as a result of cleaning by burning off. In such

cases gaseous decomposition products are formed. Decomposition

accelerates above 300 °C approximately, the initial products formed

being mainly tetrahydrofuran and water. At temperatures above about

350 °C small quantities of aldehydes and saturated and unsaturated

hydrocarbons are also formed. When Ultradur® is properly processed

and there is adequate suction at the die no risks to health are to be

expected. The workplace should be adequately ventilated when Ultradur®

is being processed.

Incorrect processing includes e. g. high thermal stresses and long

residence times in the processing machine. In these cases there is the

risk of elimination of pungent-smelling vapors and gases which can be

a hazard to health. Such a failure additionally becomes apparent due to

brownish burn marks on the moldings. This is remedied by ejection of

the machine contents into the open air and reducing the cylinder tem-

perature at the same time. Rapid cooling of the damaged material, e. g.

in a water bath, reduces nuisances caused by odors. In general mea-

sures should be taken to ensure ventilation and venting of the work

area, preferably by means of an extraction hood over the cylinder unit.

Halogen-containing flame-retardant Ultradur® grades can give rise

to corrosive and harmful degradation products due to overheating or

long residence times of the melt in the cylinder. When relatively long

downtimes occur it is therefore necessary to flush the cylinder empty

or to purge it with an Ultradur® grade which is not flame-retardant and

lower the temperature. In general we recommend careful extraction by

suction in the area of the nozzle. In the event of fires involving flame-

retardant grades containing halogen compounds toxic compounds can

be produced which should not be inhaled.

Toxicological information, regulationsUltradur® grades are not hazardous substances. No detrimental effects

to people engaged in the processing of Ultradur® have come to light

when the material has been correctly processed and the work areas

have been well ventilated.

Food safety legislationSome standard-grades of our Ultradur® product line are in conformity

with the current regulations for food contact in Europe and USA with

respect to their composition. In addition the Recommendations of

the German BfR, – The governmental institute for risk assessment

(Bundesinstitut für Risikobewertung, former BgV V/ BGA) – are fulfilled.

In case of detailed information about the food contact status for a

certain standard grade, a colored Ultradur® grade or a special grade

please contact BASF Aktiengesellschaft (plastics.safety@basf.com)

directly. We are pleased to send you a food contact compliance letter

with respect to the regulations in force at present.

Delivery and storage

Standard packaging includes the 25-kg bag and the 1000 kg octabin

(octagonal container). Other forms of packaging are possible subject

to agreement. All containers are tightly sealed and should be opened

only immediately prior to processing. Further precautions for prelimi-

nary treatment and drying are described in the processing section of

the brochure. The bulk density is depending on the product about

0.5 to 0.8 g /cm3.

Ultradur® and the environment

Storage and transportationUnder normal conditions Ultradur® can be stored for unlimited periods.

Even at elevated temperatures, e. g. 40 °C in air, and under the action

of sunlight and weather no decomposition reactions occur (cf. sections

“Delivery and storage” and “Outdoor performance”).

Ultradur® is not a hazardous material as defined by the German ordi-

nance on hazardous materials of 26.08.86 and hence is not a hazard-

ous material for purposes of transportation (cf. Ultradur® safety data

sheet).

Ultradur® is assigned to the German water pollution class 0, i. e.

Ultradur® poses no risk to groundwater.

General information

41

Waste disposalSubject to local authority regulations Ultradur® can be dumped or incin-

erated together with household garbage. The calorific value of unrein-

forced grades amounts to 29,000 to 32,000 kJ/kg (Hu according to

DIN 51900).

The burning behavior of Ultradur® is described in the section “Ultradur®

and its characteristic properties”.

RecyclingLike other production wastes, sorted Ultradur® waste materials, e. g.

ground up injection-molded parts and the like, can be fed back to

a certain extent into processing depending on the grade and the

demands placed on it. You can find further information about this under

the item (see section “Reprocessing and recycling scrap”).

Quality management certification

Quality management is a central component of BASF’s corporate

strategy. A major goal is customer satisfaction.

The Business Unit Engineering Plastics Europe of BASF Aktien gesell-

schaft has a quality assurance system in accordance with ISO/ TS

16949 certified by the German Association for the Certification of Qual-

ity Management Systems (DQS). The certification includes all services

which the business unit provides in connection with the development,

production and marketing of Ultraplasts: product and process develop-

ment, production and customer service. Constant internal audits and

training programs for staff ensure the continuing operational capability

and steady development of the quality assurance system.

Ultradur® Nomenclature

Ultradur® commercial grades are designated by either the letter B or S,

followed by a four-digit number.

Ultradur® B = PBT or PBT + PET

Ultradur® S = PBT + ASA

The letter behind the number denotes reinforcement or filler materials:

G = glass fibers

K = glass beads

M = minerals

and the number after this denotes the approximate amount of

additive, e. g.:

2 = 10 parts by weight

4 = 20 parts by weight

6 = 30 parts by weight

10 = 50 parts by weight

Color shades are identified by the code for the grade in question fol-

lowed by the name of the color and a three- to five digit color number.

Colors

Uncolored Ultradur® has an opaque white color.

Ultradur® grades are supplied in both uncolored and colored forms. All

shades are free of cadmium pigments.

Ultradur® grades can also be colored by customers themselves. Our

Ultraplaste-Infopoint will be happy to provide further information on

request.

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Connectors

42

Kunststoffe der BASF

Das Sortiment auf einen Blick

General information

Autofroth®* Polyurethane system PU

Basotect ® Foam from melamine resin MF

Capron® Polyamide PA

Cellasto®* Components made from microcellular PU elastomers PU

CeoDS®* Multifunctional composits made from Cellasto components PU

Colorflexx ® Service for the self-coloring of polystyrene and ABS

CosyPUR®* PU soft foam system PU

Ecoflex ® Biodegradable plastic /polyester

Ecovio® Biodegradable plastic /polyester on the basis of renewable raw materials

Elastan®* Systems for sports field surfaces PU

Elastoclear ®* PU system PU

Elastocoat ®* PU systems as coating and casting compounds PU

Elastocoast ®* PU systems as coating and casting compounds PU

Elastocore®* PU cast system PU

Elastoflex ®* Soft polyurethane foam systems PU

Elastofoam®* Soft integral polyurethane foam systems PU

Elastollan®* Thermoplastic polyurethane elastomers PU

Elastolit ®* Rigid integral polyurethane foam systems and RIM systems PU

Elastonat ®* Flexible integral polyurethane systems PU

Elastopan®* Polyurethane shoe foam systems PU

Elastopir ®* Rigid polyurethane foam systems PU

Elastopor ®* Rigid polyurethane foam systems PU

Elastoskin®* Flexible integral polyurethane systems PU

Elastospray ®* PU spray foam system PU

Elasturan®* Systems as cold curing cast elastomers PU

Lupranat ®* Diisocyanates PU

Lupranol®* Polyether polyols PU

Lupranol®* Balance Polyether polyols PU

Lupraphen®* Polyether polyols PU

Luran® Styrene /acrylonitrile copolymer SAN

Luran® S Acrylonitrile /styrene /acrylate polymer ASA

Luran® SC Acrylonitrile /styrene /acrylate polymer and polycarbonate ASA + PC

Miramid® Polyamide PA 6, PA 66

Neopolen® E Polyethylene foam EPE

Neopolen® P Polypropylene foam EPP

Neopor ® Expandable polystyrene PS-E

Palusol® Alkali silicate

PERMASKIN® System for coating components

Peripor ® Expandable polystyrene PS-E

PlasticsPortalTM Web-based e-Commerce platform for solutions and information

Pluracol®** Polyether polyols PU

Polystyrol, impact-modified Polystyrene HIPS PS-I

Polystyrol, standard Polystyrene GPPS PS

SPSTM* Steel-polyurethane systems PU

Styrodur ® C Extruded rigid polystyrene foam XPS

Styroflex ® Styrene / butadiene block copolymer SB

Styrolux ® Styrene / butadiene block copolymer SB

Styropor ® Expandable polystyrene PS-E

Terblend® N Acrylonitrile / butadiene /styrene polymer and polyamide ABS + PA

Terluran® Acrylonitrile / butadiene /styrene polymer ABS

Terluran® HH Acrylonitrile / butadiene /styrene polymer ABS

Terlux ® Methyl methacrylate /acrylonitrile / butadiene /styrene polymer MABS

Ultradur ® Polybutylene terephthalate PBT, (PBT+ ASA)

Ultraform® Polyoxymethylene POM

Ultramid® Polyamide PA 6, 66, 6 / 66, 6 / 6T

Ultrason® E Polyethersulfone PESU

Ultrason® S Polysulfone PSU

Subject Index

Absorption of moisture 26Adhesion 12Air flow sensor 39Airbag connector 21Automotive electronics 11Automotive engineering 4

Back pressure 28Behavior on exposure to weather 23Bristles 8

Charging simulation 24Circuit breaker 7Clip 5Coefficient of sliding friction 19Colors 11, 41Cylinder temperature control 28

Delivery 40Dial caliper 9Dielectric constant 21Dielectric dissipation factor 21Door handle 23Drying 24

Eco-efficiency analysis 12Electrical engineering and electronics 6Electrical properties 21Elongation 14Embossing 39Environment 40 f.Exposure to heat 20Extrusion 34 ff.

Fabrication 38 f.Finishing processes 38 f.Fire behavior 21 f. – General notes 21 – Tests 22Flexural fatigue strength 18Flow behavior 29Flowability 30Food safety legislation 40

General notes 24 ff.

Headlamp 4, 31Heat aging resistance 20

Impact failure energy 16Impact strength 16Incadescent wire test 23Injection molding 27 ff.Injection pressure 30Injection speed 29Injection unit 27Instrument panel 13

Joining methods 38 f.

Load calculation 24Loading – cyclic 18 – long-term static 16Loose buffer tubes for optical fibers 6, 24Low-temperature impact resistance 16

Machining 38Masterbatch distribution 11Mechanical engineering 8Mechanical properties 14 ff.Mechatronic control unit 7Metallization 39Metering 28Mirror acuator housing 4, 19Modulus of elasticity 14Moisture 24Mold design 27Mold surface temperature 29Molex connector 12Motor circuit breakers 21Moving platen 20

Nanotechnology 10Nomenclature 41

Peripheral screw speed 28Plug-in connector 5, 8, 27Polymer degradation 29Precision engineering 8Printing 39Process simulation 24Processing example 35, 36, 37Processing temperature 28Product range 10, 13

Production of – Bristles 36, 37 – Films 36, 37 – Monofilaments 36, 37 – Profile sections 35 – Semi-finished products 35 – Sheet 35 – Tubes 36Properties 10 ff.Pump pressure housing 9

Quality management certification 41

Recycling 41Regulations 40Residence time 28Resistance to chemicals 23

Safety notes 40Screw geometry 26, 34 f.Self-coloring 26Shear modulus 14Shower head 9Shrinkage 30 ff. Sliding roof frame 5Steering angle sensor 6Steering wheel module 33Storage 40Stress-strain diagrams 16, 17, 18Structure simulation 25

Tensile strength 15Test box 30Thermal properties 20Three-section screw 26Toughness 16Toxicological information 40Transportation 40Tribological properties 19

Ultradur® High Speed 10 ff.

Varnishing 39Viscosity 10

Warpage 33Waste disposal 41

Yield stress 15

43

gEn

ErA

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MA

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nPlastics from BASFThe product range at a glance

NoteThe data contained in this publication

are based on our current knowledge and

experience. In view of the many factors

that may affect processing and application

of our product, these data do not relieve

processor from carrying out own inves-

tigations and tests neither do these data

imply any guarantee for certain properties

nor the suitability of the product for a spe-

cific purpose. Any descriptions, drawings,

photographies, data, proportions, weights

etc. given herein may change without prior

information and does not constitute the

agreed contractual quality of the product.

It is the responsibility of the recipient of

our products to ensure that any propri-

etary rights and existing laws and legisla-

tion are observed. (September 2007)

Please visit our websites:

BASF Plastics:www.plasticsportal.com (World)

www.plasticsportal.eu (Europe)

Additional information on specific products:www.plasticsportal.eu/name of product

e. g. www.plasticsportal.eu/ultradur

Polyurethanes:www.basf.com/polyurethanes

www.elastogran.de

PVC and PVCD:www.solvinpvc.com

® = reg. trademark of BASF Aktiengesellschaft®* = reg. trademark of Elastogran GmbH®** = reg. trademark of BASF Corporation

TM = trademark of BASF AktiengesellschaftTM* = trademark of Elastogran GmbH

Autofroth®* Polyurethane system PU

Basotect ® Foam from melamine resin MF

Capron® Polyamide PA

Cellasto®* Components made from microcellular PU elastomers PU

CeoDS®* Multifunctional composits made from Cellasto components PU

Colorflexx ® Service for the self-coloring of polystyrene and ABS

CosyPUR®* PU soft foam system PU

Ecoflex ® Biodegradable plastic /polyester

Ecovio® Biodegradable plastic /polyester on the basis of renewable raw materials

Elastan®* Systems for sports field surfaces PU

Elastoclear ®* PU system PU

Elastocoat ®* PU systems as coating and casting compounds PU

Elastocoast ®* PU systems as coating and casting compounds PU

Elastocore®* PU cast system PU

Elastoflex ®* Soft polyurethane foam systems PU

Elastofoam®* Soft integral polyurethane foam systems PU

Elastollan®* Thermoplastic polyurethane elastomers PU

Elastolit ®* Rigid integral polyurethane foam systems and RIM systems PU

Elastonat ®* Flexible integral polyurethane systems PU

Elastopan®* Polyurethane shoe foam systems PU

Elastopir ®* Rigid polyurethane foam systems PU

Elastopor ®* Rigid polyurethane foam systems PU

Elastoskin®* Flexible integral polyurethane systems PU

Elastospray ®* PU spray foam system PU

Elasturan®* Systems as cold curing cast elastomers PU

Lupranat ®* Diisocyanates PU

Lupranol®* Polyether polyols PU

Lupranol®* Balance Polyether polyols PU

Lupraphen®* Polyether polyols PU

Luran® Styrene /acrylonitrile copolymer SAN

Luran® S Acrylonitrile /styrene /acrylate polymer ASA

Luran® SC Acrylonitrile /styrene /acrylate polymer and polycarbonate ASA + PC

Miramid® Polyamide PA 6, PA 66

Neopolen® E Polyethylene foam EPE

Neopolen® P Polypropylene foam EPP

Neopor ® Expandable polystyrene PS-E

Palusol® Alkali silicate

PERMASKIN® System for coating components

Peripor ® Expandable polystyrene PS-E

PlasticsPortalTM Web-based e-Commerce platform for solutions and information

Pluracol®** Polyether polyols PU

Polystyrol, impact-modified Polystyrene HIPS PS-I

Polystyrol, standard Polystyrene GPPS PS

SPSTM* Steel-polyurethane systems PU

Styrodur ® C Extruded rigid polystyrene foam XPS

Styroflex ® Styrene / butadiene block copolymer SB

Styrolux ® Styrene / butadiene block copolymer SB

Styropor ® Expandable polystyrene PS-E

Terblend® N Acrylonitrile / butadiene /styrene polymer and polyamide ABS + PA

Terluran® Acrylonitrile / butadiene /styrene polymer ABS

Terluran® HH Acrylonitrile / butadiene /styrene polymer ABS

Terlux ® Methyl methacrylate /acrylonitrile / butadiene /styrene polymer MABS

Ultradur ® Polybutylene terephthalate PBT, (PBT+ ASA)

Ultraform® Polyoxymethylene POM

Ultramid® Polyamide PA 6, 66, 6 / 66, 6 / 6T

Ultrason® E Polyethersulfone PESU

Ultrason® S Polysulfone PSU

® =

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Tel.: +49 621 60-78780Fax: +49 621 60-78730

E-Mail: ultraplaste.infopoint@basf.com

Request of brochures: KS / KC, E100

Fax: + 49 621 60 - 49497