ANEXO 1: CONTROL DE CALIDAD

ANEXO 1: CONTROL DE CALIDAD

1. HOJA DE EMBALAJE.......................................................................................................................... 2

2. DIAGRAMA DE FLUJO DEL PROCESO ........................................................................................... 11

3. ANÁLISIS MODAL DE FALLOS Y EFECTOS (FMEA) ...................................................................... 13

4. PLAN DE CONTROL ......................................................................................................................... 21

19/06/2017

1

OPERARIOS

INSPECTORES

AUDITORES

COLIMATORS MODULE LEDRef. Novatec: 151.044.00

Ref. cliente: 90113814

Rev.306/03/2017

LAY-OUT

AYUDA VISUAL

PAUTA DEREVISIÓN

HOJA EMBALAJE

HISTORICO DEINCIDENCIAS

HOJA DEPROCESO

INICIOCOLIMATORS MODULE LED

Rev.306/03/2017

Ref. Novatec: 151.044.00Ref. cliente: 90113814

OPERARIOS

2

19/06/2017

2

LAY-OUTHISTORICO DE INCIDENCIAS

DEFECTOS ACEPTABLES

HOJA DE CONTROL

REGISTRO DE FORMACIÓN

AYUDA VISUAL

HOJA DEPROCESOPAUTA DEREVISIÓN


Rev.306/03/2017


INSPECTORES

AYUDA VISUAL

PAUTA DEREVISIÓN

HISTORICO DEINCIDENCIAS

HOJA DEAUDITORIAS

HOJA DEEMBALAJE

DEFECTOSACEPTABLES


Rev.306/03/2017


AUDITORES

3

19/06/2017

3

PROCESS LAY-OUT 2/400

PALET

PIEZAS OK

RH-LH

MAQUINA

DE

INYECCIÓN

2-400

CIN

TA

Piezas OK

RH-LHSCRAP

CELLAIR

MUESTRA

OK

MESA

REVISION

COLIMATORS MODULE LED

EMBALAJE

VACIO


OA

P

Rev.306/03/2017 MENU OPE INS

PUESTO DE TRABAJO 2/400COLIMATORS MODULE LED



4

19/06/2017

4

AYUDA VISUAL DISTINCIÓN DE CAVIDADES

CAV 1


CAV 2 CAV 3 CAV 4

CAV 1· CAV 2· CAV 3· CAV 4·


CARA NO VISTA

Rev.306/03/2017

PAUTA DE REVISIÓN CARA VISTA

!GUANTES

USO OBLIGATORIO

DE GUANTES



Verificar:-Ausencia de marcas, arrastres, manchas y defectos

superficiales.

-Ausencia de rebabas, rechupes, falta de material en

contorno.

-Ausencia de defectos superficiales (racheados, falta

compactación, contaminados, marcas de expulsores,

etc.) en zona roja.

- No existencia de diferencias de brillos.

Verificar:-Ausencia rebabas, falta de material en

clipajes, patas de fijación, etc.

·Ausencia de falta de material en la zonade

clipaje.

· Ausencia de deformaciones

TIEMPO

INSPECCIÓN:5 seg

Defectos ROJO VERDE

Racheados No aceptable Aceptable

Puntosblancos/negros No aceptable Aceptable

Rechupes No aceptable Aceptable

Rayas/Roces No aceptable Aceptable

LineasFlujo No aceptable Aceptable

Ausenciabrillo No aceptable Aceptable

Inclusiones/ Burbujas No aceptable Aceptable

Polvo/humedad No aceptable Aceptable

Rebabas No aceptable No aceptable

IMAGEN REALRev.306/03/2017

5

19/06/2017

5

PAUTA DE REVISIÓN CARA NO VISTA

!GUANTES

USO OBLIGATORIO

DE GUANTES



Verificar:-Ausencia de marcas, arrastres, manchas y defectos

superficiales.

-Ausencia de rebabas, rechupes, falta de material en

contorno.

-Ausencia de defectos superficiales (racheados, falta

compactación, contaminados, marcas de expulsores,

etc.) en zona roja.

- No existencia de diferencias de brillos.

Verificar:-Ausencia rebabas, falta de material en

clipajes, patas de fijación, etc.

·Ausencia de falta de material en la zonade

clipaje.

· Ausencia de deformaciones

Rev.306/03/2017

TIEMPO

INSPECCIÓN:5 seg

Defectos ROJO VERDE

Racheados No aceptable Aceptable

Puntosblancos/negros No aceptable Aceptable

Rechupes No aceptable Aceptable

Rayas/Roces No aceptable Aceptable

LineasFlujo No aceptable Aceptable

Ausenciabrillo No aceptable Aceptable

Inclusiones/ Burbujas No aceptable Aceptable

Polvo/humedad No aceptable Aceptable

Rebabas No aceptable No aceptable

IMAGEN REAL

HOJA DE PROCESO

2º - REPETIREMOS LA REVISION COMO EL PUNTO 1 POR LA CARA

NO VISTA DE LA PIEZA COMPROBANDO TAMBIEN EL

ANGULO CORRESPONDIENTE DE ESA CARA.


METODO DE REVISION

1º - COGEMOS LA PIEZA COMO SE OBSERVA EN LA IMAGEN Y SE

REVISARA LA PASANDO POR LOS PANELES BLANCOS Y NEGROS

COMPROBANDO PRIMERO LA CARA VISTA Y EL ANGULO FRONTAL.



6

19/06/2017

6

HOJA DE CONTROL

Nº Característica Tipo Especificación Tamaño Muestra

Frecuencia MétodoControl

1 Comprobarmaterial correcto

PC Makrolon Led2245 N/A Saco Visual

2 Confirmaciónprocesohomologado

Check list arranque molde/proceso C04i09 N/A Arranque Evaluacióninspectorcalidad

3 Verificación dimensional SC PESO:17 g. +/-1 g.

1 inyectada Arranque / 8horas

Báscula

4 Verificación dimensional Verificacion con contraparte 1 inyectada Arranque / 4horas

Contraparte

5 Defectos generales deinyección

FALTA DE MATERIAL 100 % Arranque / 2horas

Comprobaciónconpiezapatrón


RAFAGAS 100% Arranque / 2horas



BRILLOS 100% Arranque / 2horas



LINEAS DEUNIÓN 100% Arranque / 2horas



PIEZADEFORMADA 100 % Arranque / 2horas



CONTAMINACIÓN Y/O PUNTOS NEGROS FUERA DE LOS TAMAÑOSESPECIFICADOS

100 % Arranque / 2horas



PIEZARECHUPADA 100 % Arranque / 2horas



PIEZA CON QUEMAZOS 100 % Arranque / 2horas



PUNTOS FRIOS 100 % Arranque / 2horas




MENU INSRev.306/03/2017

Nº Característica Tipo Especificación TamañoMuestra

Frecuencia MétodoControl


PUNTO DE INYECCIÓN FUERA DEESPECIFICACIÓN

100 % Arranque / 2horas



BURBUJAS 100 % Arranque / 2horas



REBABAS GENERALES 100 % Arranque / 2horas



SUCIEDAD / MANCHAS 100 % Arranque / 2horas



MARCAS / GOLPES 100% Arranque / 2horas



AGUJEROS POSICIONADORES NOK 100% Arranque / 2horas

Comprobaciónconcontraparte


HUMO 100 % Arranque / 2horas



GRIETAS 100 % Arranque / 2horas



AMARILLEAMIENTO 100 % Arranque / 2horas


HOJA DE CONTROLCOLIMATORS MODULE LED

MENU INSRev.306/03/2017


7

19/06/2017

7

TIPO DE EMBALAJE

EXPEDICION

Rev.306/03/2017

HOJA DE PROCESO EMBALAJECOLIMATORS MODULE LED


1º- Cogemos cellair BC y colocamos 3 piezas como se observa en laimagen.

2º-Enrollamos el cellair BC las 3 piezas. Ponemos otras 3 piezasen el cellair.

3º-Repetimos procedimiento , enrollamos las 3 piezas y

colocamos otras 3.

4º-Repetimos procedimiento , enrollamos las 3 piezas y

colocamos otras 3.

5º-Por último enrollamos las 3 piezas finales , un total de 12

piezas por cellair BC.


8

19/06/2017

8

1.-Ponemos 12 piezas envueltas en cellair BC , según hoja de proceso de embalaje.

3.-Completamos el embalaje con 5 pisos.

HOJA DE EMBALAJE EXPEDICION

DESCRIPCIÓN CÓDIGO UDS/CONTENEDOR UDS/PALET

COLIMATORS MODULE LED 151.044.00 180 7200

KLT 43270 CAJA MARRON (400X300X270) 408.000.43 1 40

LAMINA CELL AIR BC (550x380) 403.000.07 15 600

LAM. CELL AIR PE 40 330x235 403.000.09 4 160

PALET ST ( 1200 X 1000 ) 407.000.06 1/40 1

Rev.306/03/2017



-IMPORTANTE: ETIQUETA IDENTIFICATIVA EN CADA KLT DE

180 UDS Y MARCAJE DE 7200 UDS POR CADA PISO(10 CAJAS)

2.- Completamos el piso con 3 packs de 12 piezas cada uno y

separamos piso con cellair PE 40.

Nº CaracterísticaTipo

EspecificaciónTamaño

MuestraFrecuencia MétodoControl

1 Comprobarreferencia correcta

Fechador de referencia / Fotografía versión 1 inyectada Al comienzode la auditoria

Comprobar en la ayuda visual

2 Verificar código de la pieza con código de la etiqueta

Código de la pieza 1 inyectada Al comiendode la auditoria

Comprobar en la ayuda visual

3 Defectos generales de inyección

FALTA DE MATERIAL 100% 100% Comprobación con pieza patrón


RAFAGAS 100% 100% Comprobación con piezapatrón


BRILLOS 100% 100% Comprobación con piezapatrón


LINEAS DEUNIÓN 100% 100% Comprobación con piezapatrón


PIEZADEFORMADA 100% 100% Comprobación con piezapatrón


CONTAMINACIÓN Y/O PUNTOS NEGROS FUERA DE LOS TAMAÑOSESPECIFICADOS

100% 100% Comprobación con piezapatrón

9Defectos generales de

inyección PIEZARECHUPADA 100% 100%Comprobación con pieza

patrón

10

Defectos generales de inyección PIEZA CON QUEMAZOS 100% 100%

Comprobación con pieza patrón


inyección PUNTOS FRIOS 100% 100%Comprobación con pieza

patrón


inyección PUNTO DE INYECCIÓN FUERA DE ESPECIFICACIÓN 100% 100%Comprobación con pieza

patrón

Rev.306/03/2017

HOJA DE AUDITORIASCOLIMATORS MODULE LED


9

19/06/2017

9

HOJA DE AUDITORIAS

Nº CaracterísticaTipo

EspecificaciónTamaño

MuestraFrecuencia MétodoControl

13 Defectos generales de inyección BURBUJAS 100% 100% Comprobación con pieza patrón

14 Defectos generales de inyección REBABAS GENERALES 100% 100% Comprobación con pieza patrón

14 Defectos generales de inyección SUCIEDAD / MANCHAS 100% 100% Comprobación con pieza patrón

14 Defectos generales de inyección MARCAS / GOLPES 100% 100% Comprobación con pieza patrón

14 Defectos generales de inyección AGUJEROS POSICIONADORES NOK 100% 100% Comprobación con piezapatrón

14 Defectos generales de inyección HUMO 100% 100% Comprobación con piezapatrón

14 Defectos generales de inyección GRIETAS 100% 100% Comprobación con piezapatrón

14 Defectos generales de inyección AMARILLEAMIENTO 100% 100% Comprobación con piezapatrón

17 Verificación del embalaje Piezas embaladas en el embalaje ok Cadapalet 100 % Visual con pauta deembalaje

18 Verificación de etiquetaje Comprobar que la etiquetacorresponde con la pieza

Cadaklt 100 % Visual con pauta deembalaje

19 Pauta de revisión Tiempos de revisión cara vista y novista

Cadapieza 100% Visual

Rev.306/03/2017 MENU AUD



REGISTRO DE CAMBIOS

•Nº REV •FECHA •DESCRIPCION •MODIFICADOPOR:

• REV 1 • 30/09/2016 • CREACION DE DOCUMENTO • CRISTIAN DURÁ

• REV 2 • 03/02/2017 • MODIFICACIÓN DE PAUTA DE REVISIÓN • CRISTIAN DURÁ

• REV 2 • 06/03/2017 • MODIFICACIÓN DE EMBALAJE EXPEDICION • CRISTIAN DURÁ

Rev.306/03/2017



10

STOCK TRANSPORTE CONTROL OPERACION ARRANQUE PUESTA A PUNTO

PROVEEDOR

PUESTA A PUNTO MEDIOS.

60 AUDITORÍA PT

STOCK M.PRIMAZONA PREDEFINIDA

TRANS. INTERNO

MP NOK

CONTROL RUTINARIO CALIDAD

IDENTIFICACION PRODUCCION

30. ARRANQUE SERIE

IDENTIFICACION MP

10 CONTROL MP

40 INYECCIÓN SERIE

TRANS. INTERNO

DIAGRAMA DE FLUJO DEL PROCESO C0101i01 rev 1

LIBERACIÓN PRIMERA PIEZA OK

TRANS. INTERNO

STOCK MP. ALMACEN PRODUCCIÓN

TRANS. INTERNO

20. TRATAMIENTO DEL MATERIAL

50 EMBALAJE

TRANS. INTERNO

LIBERACION PALET

SC

SC

PAUTA INSPECCIÓN MP

C03i05

ETIQUETA NOVATEC MP

C03i02

ORDEN FABRICACION

Vº Bº CALIDAD INICIO OTCHECK LIST CALIDAD C04i09

PAUTA CONTROL C04i06

INSTRUCCION DE

IDENTIFICACION IT_PRC04_340

Nº MAQUINA INY UBICACIÓN MEDIOS S/LAYOUT

C04i06CHECK AUXILIAR

PRESENTACION -- C04i06

AUTOCONTROL AUDITS

FICHAPARAMETROS C04i03 CHECK MONTADOR

CHECK TECNICO

SEGUN ORDEN PRODUCCION

USANDO CHECK LIST

MONTADOR


AUTOCONTROL PRODUCCION


REGISTRO PRODUCCION


INSTRUCCION DE LIBERACION

IT_PRC04_340

NOK

NOK

NOK

NOK

SCAP ARRANQUE

AREA MAT NO CONF

SCRAPTRASPASO DE ALMACENES

SEGUN INSTRUCCION

IT_PRC05_210

NOK

MATERIA PRIMA

1-PC Makrolon Led 2245(206.020.10)

Cliente: VALEORef: 151.044.00Pz: COLIMATORS MODULE LEDREF cliente – 90113814

11

VºBº por: J.DIB

Dpto: PROYECTOS

Fecha: 30/09/2016

REV FECHA

1 30/09/2016

30/09/2016

CALIDAD

I.LORENTEElaborado por:

Dpto:

Fecha:

MOTIVO

CREACION DE DOCUMENTACION

70 STOCK ALMCEN P. TERMINADO

80 EXPEDICIÓN

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EXPEDICION

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24

ANEXO 2: CERTIFICADOS DE INSPECCIÓN DE MATERIAL

1. CERTIFICADO PRIMERO ................................................................................................................... 2

2. CERTIFICADO SEGUNDO .................................................................................................................. 3

3. CERTIFICADO TERCERO .................................................................................................................... 5

4. CERTIFICADO CUARTO ..................................................................................................................... 7

______________________________________________________________________Nombre del producto Número de productoMAKROLON LED2245 61502082550207PE-BAG 25KG HT-PAL 1250KG______________________________________________________________________Datos del pedido del clienteDestinatario de la mercancía Cantidad pedida Número de pedido del cliente Número de producto del cliente999247 COV-c/o ValeoIluminacion 12500 KG 5502010833 90095818______________________________________________________________________Datos del pedidoNúmero de pedido Número de albarán Cantidad a enviar Número de unidades enviadas3009645505 / 10 4002337607 / 10 12500 KG 10______________________________________________________________________Datos del loteLote n° Cantidad a enviar01PM6L0830 12500 KG______________________________________________________________________Inspecciones Metodo Resultado Especificación Unidad______________________________________________________________________MVR ISO 1133 33,0 30,0 - 38,0 cm³/10min

300°C / 1.2 kgMFR ASTM D 1238 34,8 31,7 - 40,1 g/10min

300°C / 1.2 kgDelta a DIN 6174 / ASTM D 2244 -0,01 -0,15 - 0,15Delta b DIN 6174 / ASTM D 2244 -0,11 -0,30 - 0,30______________________________________________________________________

Para cualquier pregunta, su interlocutor es:Dr. Michael Mutz PCS-RD-TPQM-PSM

Fax: +49 214 6009 963142Mail: [email protected]

1. El presente documento ha sido creado de forma electrónica y es válido sin necesidad de firma.2. La información y los valores mencionados no aseguran la adecuación de la sustancia para ningún fin determinado ni conllevan ningunagarantía. Dicha información no exime al cliente de realizar los controles de recepción de mercancías.3. Estos valores han sido confirmados por un inspector de recepción independiente contratado por Covestro.

VALEO ILUMINACION S.A.Enrique Serranoc/Torneros(muelles) c/Forja(oficina23600 MARTOS (JAEN)SPANIEN

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Covestro Deutschland AGKaiser-Wilhelm-Allee51373 Leverkusen

2

______________________________________________________________________Nombre del producto Número de productoM.LED2245P 000000 BA125X 61502074Kunden-Mat.Nr. 90008133/5502001666______________________________________________________________________Datos del pedido del clienteDestinatario de la mercancía Cantidad pedida Número de pedido del cliente Número de producto del cliente999247 COV-c/o ValeoIluminacion 20000 KG 5502001666 90008133______________________________________________________________________Datos del pedidoNúmero de pedido Número de albarán Cantidad a enviar Número de unidades enviadas3009678143 / 10 4002445468 / 10 20200 KG 17______________________________________________________________________Datos del loteLote n° Cantidad a enviar01PM6N1120 200 KG______________________________________________________________________Inspecciones Metodo Resultado Especificación Unidad______________________________________________________________________MVR ISO 1133 34,9 30,0 - 38,0 cm³/10min


300°C / 1.2 kgYellowness Index ASTM E 313 ( D65/10° ) 1,0 <= 1,8______________________________________________________________________





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______________________________________________________________________Nombre del producto Número de productoM.LED2245P 000000 BA125X 61502074Kunden-Mat.Nr. 90008133/5502001666______________________________________________________________________Datos del pedido del clienteDestinatario de la mercancía Cantidad pedida Número de pedido del cliente Número de producto del cliente999247 COV-c/o ValeoIluminacion 20000 KG 5502001666 90008133______________________________________________________________________Datos del pedidoNúmero de pedido Número de albarán Cantidad a enviar Número de unidades enviadas3009678143 / 10 4002445468 / 10 20200 KG 17______________________________________________________________________Datos del loteLote n° Cantidad a enviar01PM7A0080 20000 KG______________________________________________________________________Inspecciones Metodo Resultado Especificación Unidad______________________________________________________________________MVR ISO 1133 34,4 30,0 - 38,0 cm³/10min







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______________________________________________________________________Nombre del producto Número de productoM.LED2245P 000000 BA125X 61502074Kunden-Mat.Nr. 90008133/5502001666______________________________________________________________________Datos del pedido del clienteDestinatario de la mercancía Cantidad pedida Número de pedido del cliente Número de producto del cliente999247 COV-c/o ValeoIluminacion 20000 KG 5502001666 90008133______________________________________________________________________Datos del pedidoNúmero de pedido Número de albarán Cantidad a enviar Número de unidades enviadas3009678143 / 10 4002445468 / 10 20200 KG 17______________________________________________________________________Datos del loteLote n° Cantidad a enviar01PM6N1120 200 KG______________________________________________________________________Inspecciones Metodo Resultado Especificación Unidad______________________________________________________________________MVR ISO 1133 34,9 30,0 - 38,0 cm³/10min







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8

ANEXO 3: ESPECIFICACIONES TÉCNICAS DEL MATERIAL

1. RESISTENCIA QUÍMICA DEL MAKROLON ...................................................................................... 2

2. CARACTERÍSTICAS MAKROLON LED2245 ...................................................................................... 7

3. PREPARACIÓN DEL MATERIAL: SECADO ..................................................................................... 10

Page 1 of 5 File No.: KU28057-0409 en Issue 2004-09-28 (replaces ATI 0082 dated 1995-06-01)

Makrolon® Technical Information

The chemical resistance of Makrolon® The property values listed in the Makrolon® Techni-cal Information have been established on standard-ized test specimens produced in accordance with the standardized procedures. The tests are gener-ally performed in a surrounding medium of clean air. If a finished part in Makrolon® is in contact with other media, its properties may undergo consider-able change.

1. Influencing parameters

The extent to which the properties of the material are influenced is a function of the:

- composition of the surrounding media

- temperature

- duration of exposure

- level of inherent or applied stress and strain prevailing in the molded part

2. Types of damage

A distinction can be drawn between different types of damage. It is also possible for individual sur-rounding media to act simultaneously following more than one type of damage.

Dissolution or swelling

Low-molecular, aromatic, halogenated and polar components migrate into the polycarbonate. The damage can range from a tacky surface to com-plete dissolution.

Stress cracking

A number of chemicals penetrate the surface slightly, in small quantities, and cause a concentra-tion gradient to develop in the polycarbonate, thereby loosening the bonding forces between the molecules. Stresses prevailing in the molded part then relax by causing stress cracks to form. Stress

cracks can affect the appearance of a molded part. The pronounced notched effect of the stress cracks leads to a pronounced deterioration in a number of mechanical properties - and particularly in those that can be derived from the impact, flexural and tensile tests. With transparent grades, the stress cracks are generally easy to see. In opaque grades it is frequently impossible to detect them. Mechani-cal tests are then required, with the impact strength or flexural strength generally being taken as indica-tor properties in laboratory tests.

Molecular degradation

A number of the properties of Makrolon® are deter-mined by the size of its molecules. If a contact me-dium causes a reduction in molecular weight through a chemical reaction then this will affect especially the tough and resilient properties of the material. The molecular weight level has virtually no influence on electrical properties and only a slight influence on thermal properties.

As an ester of bisphenol A and carbonic acid, poly-carbonate will gradually be split into these compo-nents again by water at a high temperature, for instance. Alkalis act as pronounced catalysts during hydrolysis. Acid catalysis is only weak. Alcohols and carboxylic acids can similarly lead to molecular degradation through ester interchange. Amines can cause pronounced molecular damage in some cases through transamination. Ammonia and low-molecular, aliphatic, primary and secondary amines are particularly aggressive in the presence of traces of water. High-molecular, slightly basic amines are less critical.

Oxidative damage

The potential oxidative damage that can occur with a number of other polymers, such as natural rubber and polypropylene plays a relatively minor role with polycarbonate. Makrolon® is relatively stable vis-à-vis oxidizing agents. Hence, the reaction with at-mospheric oxygen is only of minor significance, even in the absence of stabilizers and at tempera-

2



tures in excess of 100 °C. This is why Makrolon®

displays remarkably high stability vis-à-vis 10 % nitric acid and hydrogen peroxide by comparison to a large number of other polymers.

Influence of temperature and duration of expo-sure

The time that elapses before damage occurs be-comes shorter as the temperature rises. The expo-sure time required for initial damage ranges from just a few seconds to more than 1000 hours as a function of the chemical involved, the temperature and the stress level. When molded parts with pro-nounced stresses are immersed in propylene car-bonate, for instance, stress cracks will occur in less than one minute. Low-stress moldings in appropri-ate Makrolon® grades, by contrast, will withstand frequent cleaning with a 2 % aqueous sodium hy-droxide solution at 80 °C. The residence time should be kept short and the aggressive medium removed from the molded part surface in its entirety after use.

3. Molded part testing to meet practical requirements

If finished parts are likely to come into contact with aggressive media during use, then it is essential to subject them to the appropriate form of testing. Information on compatibility that has been obtained in the laboratory can only be viewed as a guide. The stress states prevailing in the molded part, together with the force acting from outside, can lead to considerably different results.

Short-time contact with aggressive media at below the damage threshold assumes that the medium is removed in its entirety and does not remain in pro-longed contact with the material through capillary forces, such as at screw connections or the like. Practical tests are absolutely essential for applica-tions of this type.

In the case of contact with what are essentially compatible solids, it is possible for a component which is capable of migration to move over to the polycarbonate in the course of long-term contact and damage it. One example of this is the contact between polycarbonate and plasticized PVC, in components like terminal strips and PVC insulation,

where plasticizers such as dioctyl phthalate, which trigger stress corrosion cracking, cause damage to the polycarbonate.

Stress crack will only develop, however, if tensile stresses prevail in the molded part as a result of its production and/or are applied from the outside. If the molded part is completely stress free or is sub-ject solely to compressive stress, then no stress cracking will occur. If a plasticized PVC tube is mounted on a stress-free polycarbonate pipe, for instance, the polycarbonate will simply swell slightly (the amount of swelling increasing with the plasticizer migration), and the components will weld together. Practical tests on the finished part are absolutely essential in this case too.

It should be borne in mind that the composition of a number of technical substances is subject to change. A laboratory test can only supply informa-tion on the batch that has been tested.

Our test laboratories have tested a series of chemi-cals and commercial products to establish the influ-ence that they have on polycarbonate. If the infor-mation given below does not suffice for your pur-poses, kindly contact your Bayer service represen-tative, who will establish whether we have any fur-ther experience in respect of your particular ques-tion.

4. Compatibility assessment methods

The simplest method is the template method (flex-ural strip method to DIN 53449-3). This involves test pieces of 80 x 10 x 4 mm³ in size being clamped to curved templates in such a way that a graduated outer fiber strain ranging from 0 to 2 % is applied. A comparative study must be conducted in air under otherwise identical conditions. What is compared is the reduction in maximum strain that produces no damage both with and without the medium.

Details on this can be found in our Technical Infor-mation Sheet "Environmental Stress Cracking - Bend strip test".

3



5. Assessment criteria

The information given in the Table that follows is based on tests to reveal the outer fiber strain as of which Makrolon® 2800 suffered damage at 23 °C, or at a higher temperature where this is indicated, over a period of 6 days. Components that lead to dam-age with an outer fiber strain of ε < 1.0 % are rou-tinely classified as incompatible.

6. Resistance

Resistance to chemicals (see table on page 4)

Resistance to oils, greases, waxes and fuels

Makrolon® is resistant to most of the industrial oils, greases and waxes tested in our laboratory over 6 days at 23 °C. A series of the products tested did not produce any inadmissible changes in test pieces made of Makrolon® 2800 after 6 days at 60 °C either. Resistance is only assured if the tech-nical products are free of low-molecular, aromatic and polar components and of other components that trigger stress corrosion cracking. It should be borne in mind that oils heated to a high temperature can decompose and then form aggressive compo-nents. Makrolon® is not resistant to the standard carburetor and diesel fuels. The low-molecular, aromatic hydrocarbons that are present in carbure-tor fuel, in particular, cause cracking in parts that are subject to stress.

Resistance to sealing compounds and plastics

Makrolon® is resistant to a large number of sealing compounds for 6 days at 23 °C and for 6 days at 60 °C.

Details on this can be found in our Technical Infor-mation Sheet "Sealing compounds for use with Makrolon® ".

A condition of this resistance is that there should be no aggressive components, such as plasticizers or solvents, which migrate out of the compound and attack the polycarbonate. The same situation also applies to contact with other plastics. Although high-molecular plastics have an inert effect on

Makrolon®, the polycarbonate can be damaged by migrating plasticizer (e.g. plasticized PVC), physical blowing agents (from a number of foamed plastics) and out gassing amines (e.g. decomposition prod-ucts from vulcanization accelerators in rubber or amines from amino plastic). In the same way, if polycarbonate is subjected to joint heat treatment with polyamide 6, it is possible for ε caprolactam to migrate from the PA to the PC and cause degrada-tion.

Tests should thus be conducted in each case in order to establish whether the material components will be sufficiently compatible in service.

Resistance to adhesives

Makrolon® is resistant to a series of adhesives.

Details on this can be found in our Technical Information Sheet "The Adhesive Bonding of Makrolon® ".

Resistance to paints

In the case of paints containing solvents, stress cracking or swelling may occur as a function of the solvent and the flash-off conditions. Through cor-rectly-tailored solvent aggressiveness and flash-off conditions, it is possible to achieve paints that do not damage polycarbonate. The hardened paint can even enhance the media compatibility of the fin-ished part.

Makrolon® is also sufficiently resistant to two-component paints if the individual components do not cause any damage in the short period between the application and the hardening of the paint. Makrolon® is not resistant to turpentine and hence not resistant to paints containing turpentine either.

4



Resistance to chemicals

6 days / 23 °C 6 days / 50 °C

Acetic acid, 10 % in water + +

Acetone swells

Ammonia, 0.1 % in water -

Ammonium nitrate, 10 % in water/neutral + -

Benzene swells

Benzine (free from aromatic hydrocarbons) + +

Butyl acetate -

Carbon tetrachloride swells

Chloroform dissolves

Citric acid, 10 % in water +

Dibutyl phthalate -

Diethyl ether -

Dimethyl formamide dissolves

Dioctyl phthalate -

Dioxane dissolves

Ethanol (pure) + +

Ethyl acetate swells

Ethylamine -

Ethylene chloride swells

Ethylene glycol, 1:1 with water + +

Glycerin reacts

Hexane + +

Hydrochloric acid, 10% in water + +

Hydrogen peroxide, 30 % in water +

Iron(III) chloride, saturated/aqueous solution + +

Isooctane (2,2,4-trimethyl pentane), pure + + (40 °C)

Isopropanol (pure) +

Methanol -

Methyl ethyl ketone swells

Methylamine reacts

Methylene chloride dissolves

Nitric acid, 10 % in water +

n-propanol - (30 °C)

Ozone, 1 % in air -

Paraffin, paraffin oil, pure/free from aromatic hydrocarbons + +

Phosphoric acid, 1 % in water + -

Potassium hydroxide, 1 % in water -

Propane + +

Silicone oil + +

Sodium carbonate (soda), 10 % in water + - (70 °C)

Sodium chloride, saturated/aqueous solution + +

Sodium hydroxide (caustic soda), 1 % in water -

Sodium nitrate, 10 % in water +

Styrene -

Sulfuric acid, 10 % in water + +

Tetrachloroethane swells

Tetrachloroethylene -

Trichloroethylene swells

Tricresyl phosphate -

Triethylene glycol + +

Xylene swells

+ = resistant - = non resistant

5



Resistance to cleaning and washing agents

Cleaning and washing agents are a class of prod-ucts with many different compositions. These fre-quently contain individual components to which Makrolon® is not resistant.

Makrolon® is resistant to normal soaps but not to amines, ammonia, a small number of solvent com-ponents and a large number of high-gloss drying aids. Rinsing agents incorporating high-gloss drying aids are also unsuitable for polycarbonate in some cases.

Although high-gloss drying aids can generally be classified as compatible on the basis of short-time tests, which correspond to the short rinsing times that prevail, the decisive factor is that part of the dilute high-gloss drying aid solution is left on the surface of the polycarbonate, where it concentrates and remains on the molded part for a prolonged period of time.

Details on this can be found in our Technical Infor-mation Sheet "Cleaning, Disinfection and Sterilisa-tion of Parts in Makrolon® ".

Resistance to foods and luxury foods

Makrolon® does not normally undergo any changes when in contact with the majority of foods and lux-ury foods, under standard conditions of use. Makro-lon® is incompatible with a number of herbal and medicinal teas incorporating ethereal oils, as well as with a number of spices. Cloves, nutmeg and pimento can damage Makrolon® . It has been seen with fennel tea that brewed tea produced from fruits can contain ethereal oils in quantities that cause polycarbonate to swell.

Resistance to disinfectants, drugs and cosmetics

Some of these contain solvents or active ingredi-ents which damage Makrolon® . Polycarbonate is incompatible with nail varnish remover and nail varnish, for instance.

If the composition and action of the individual ingre-dients is known, it is frequently possible to estimate the influence that the substance will have on the properties of Makrolon® . It is even better to put the finished part through an appropriate practical test. If no empirical values are available, then a test on the finished part will always be necessary.

This information and our technical advice – whether verbal, in writing or by way of trials – are given in good faith but without warranty, and this also applies where proprietary rights of third parties are involved. Our advice does not release you from the obligation to verify the in-formation currently provided - especially that contained in our safety data and technical information sheets - and to test our products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery.

Publisher: Business Development – Injection Molding – Polycarbonates Bayer MaterialScience AG, D-51368 Leverkusen www.plastics.bayer.com

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Page 1 of 4 pages

Makrolon®

Edition 07.08.2012 ISO Datasheet

Grades / Light guides Formerly Makrolon DP1-1857; MVR (300 °C/1.2 kg) 34 cm³/10 min; light guides; PC with highesttransmission; low viscosity; easy release; injection molding - melt temperature 280 - 320 °C; availablein color code 000000 only

ISO Shortname ISO 7391-PC,MRT,(,,)-24-9

Property Test Condition Unit Standard Value-

Rheological properties

C Melt volume-flow rate 300 °C; 1.2 kg cm³/10 min ISO 1133 34

C Molding shrinkage, parallel 60x60x2 mm; 500 bar % ISO 294-4 0.65

C Molding shrinkage, normal 60x60x2 mm; 500 bar % ISO 294-4 0.7

Mechanical properties (23 °C/50 % r. h.)

C Tensile modulus 1 mm/min MPa ISO 527-1,-2 2350

C Yield stress 50 mm/min MPa ISO 527-1,-2 63

C Yield strain 50 mm/min % ISO 527-1,-2 6.0

C Nominal strain at break 50 mm/min % ISO 527-1,-2 > 50

Stress at break 50 mm/min MPa ISO 527-1,-2 60

Strain at break 50 mm/min % b.o. ISO 527-1,-2 125

Flexural modulus 2 mm/min MPa ISO 178 2350

Flexural strength 2 mm/min MPa ISO 178 97

Flexural strain at flexural strength 2 mm/min % ISO 178 7.1

Flexural stress at 3.5 % strain 2 mm/min MPa ISO 178 73

C Charpy impact strength 23 °C kJ/m² ISO 179-1eU N

C Charpy impact strength -30 °C kJ/m² ISO 179-1eU N

Charpy impact strength -60 °C kJ/m² ISO 179-1eU N

Charpy notched impact strength 23 °C; 3 mm kJ/m² ISO 7391/b.o. ISO179-1eA

60P(C)

Charpy notched impact strength -30 °C; 3 mm kJ/m² ISO 7391/b.o. ISO179-1eA

12C

Izod notched impact strength 23 °C; 3 mm kJ/m² ISO 7391/b.o. ISO 180-A 60P(C)

Izod notched impact strength -30 °C; 3 mm kJ/m² ISO 7391/b.o. ISO 180-A 12C

Izod notched impact strength 23 °C; 3.2 mm kJ/m² b.o. ISO 180-A 65P(C)

Izod notched impact strength -30 °C; 3.2 mm kJ/m² b.o. ISO 180-A 12C

C Puncture maximum force 23 °C N ISO 6603-2 4900

C Puncture maximum force -30 °C N ISO 6603-2 5900

C Puncture energy 23 °C J ISO 6603-2 55

C Puncture energy -30 °C J ISO 6603-2 60

Ball indentation hardness N/mm² ISO 2039-1 115

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Makrolon®



Thermal properties

C Glass transition temperature 10 °C/min °C ISO 11357-1,-2 145

C Temperature of deflection under load 1.80 MPa °C ISO 75-1,-2 125

C Temperature of deflection under load 0.45 MPa °C ISO 75-1,-2 138

C Vicat softening temperature 50 N; 50 °C/h °C ISO 306 145

Vicat softening temperature 50 N; 120 °C/h °C ISO 306 146

C Coefficient of linear thermal expansion, parallel 23 to 55 °C 10-4/K ISO 11359-1,-2 0.65

C Coefficient of linear thermal expansion, transverse 23 to 55 °C 10-4/K ISO 11359-1,-2 0.65

C Burning behavior UL 94 [UL recognition] 0.75 mm Class UL 94 V-2 (CL)

Burning behavior UL 94 [UL recognition] 2.9 mm Class UL 94 HB (CL)

C Oxygen index Method A % ISO 4589-2 28

Thermal conductivity 23 °C W/(m·K) ISO 8302 0.20

Resistance to heat (ball pressure test) °C IEC 60695-10-2 136

Relative temperature index (Tensile strength) [UL recognition] 1.5 mm °C UL 746B 125

Relative temperature index (Tensile impact strength) [UL recognition] 1.5 mm °C UL 746B 115

Relative temperature index (Electric strength) [UL recognition] 1.5 mm °C UL 746B 125

Glow wire test (GWFI) 1.0 mm °C IEC 60695-2-12 850



Glow wire test (GWIT) 0.75 mm °C IEC 60695-2-13 875



Burning rate (US-FMVSS) >=1.0 mm mm/min ISO 3795 passed

Flash ignition temperature °C ASTM D1929 480

Self ignition temperature °C ASTM D1929 550

Electrical properties (23 °C/50 % r. h.)

C Relative permittivity 100 Hz - IEC 60250 3.1

C Relative permittivity 1 MHz - IEC 60250 3.0

C Dissipation factor 100 Hz 10-4 IEC 60250 5

C Dissipation factor 1 MHz 10-4 IEC 60250 95

C Volume resistivity Ohm·m IEC 60093 1E14

C Surface resistivity Ohm IEC 60093 1E16

C Electrical strength 1 mm kV/mm IEC 60243-1 34

C Comparative tracking index CTI Solution A Rating IEC 60112 250

Comparative tracking index CTI M Solution B Rating IEC 60112 125M

Other properties (23 °C)

C Water absorption (saturation value) Water at 23 °C % ISO 62 0.30

C Water absorption (equilibrium value) 23 °C; 50 % r. h. % ISO 62 0.12

C Density kg/m³ ISO 1183-1 1190

Bulk density Pellets kg/m³ ISO 60 660

Material specific properties

Refractive index Procedure A - ISO 489 1.584

Haze for transparent materials 3 mm % ISO 14782 < 0.5

Luminous transmittance (clear transparent materials) 1 mm % ISO 13468-2 90

C Luminous transmittance (clear transparent materials) 2 mm % ISO 13468-2 90

Luminous transmittance (clear transparent materials) 3 mm % ISO 13468-2 > 89

Luminous transmittance (clear transparent materials) 4 mm % ISO 13468-2 > 89

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Makrolon®



Processing conditions for test specimens

C Injection molding-Melt temperature °C ISO 294 280

C Injection molding-Mold temperature °C ISO 294 80

C Injection molding-Injection velocity mm/s ISO 294 200

C These property characteristics are taken from the CAMPUS plastics data bank and are based on the international catalogue of basic data forplastics according to ISO 10350.

Impact properties: N = non-break, P = partial break, C = complete break

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Makrolon LED2245

Page 4 of 4 pages

Makrolon®


Disclaimer

General

The manner in which you use and the purpose to which you put and utilize our products, technical assistance and information (whether verbal, written or by way of production evaluations), includingany suggested formulations and recommendations, are beyond our control. Therefore, it is imperative that you test our products, technical assistance and information to determine to your ownsatisfaction whether they are suitable for your intended uses and applications. This application-specific analysis must at least include testing to determine suitability from a technical as well ashealth, safety and environmental standpoint. Such testing has not necessarily been done by us. Unless we otherwise agree in writing, all products are sold strictly pursuant to the terms of ourstandard conditions of sale which are available upon request. All information and technical assistance is given without warranty or guarantee, and is subject to change without notice. It is expresslyunderstood and agreed that you assume and hereby expressly release us from all liability, in tort, contract or otherwise, incurred in connection with the use of our products, technical assistance andinformation. Any statement or recommendation not contained herein is unauthorized and shall not bind us. Nothing herein shall be construed as a recommendation to use any product in conflict withpatents covering any material or its use. No license is implied or in fact granted under the claims of any patent. Unless specified to the contrary, the property values given have been established onstandardized test specimens at room temperature. The figures should be regarded as typical values only and not as binding limiting values. Please note that the properties can be affected by thedesign of the mold/die, the processing conditions and coloring. With respect to health, safety and environment precautions, the relevant Material Safety Data Sheets (MSDS) and product labels mustbe observed prior to working with our products.

Publisher: Global Innovations - Polycarbonates

Bayer MaterialScience AG,

D-51368 Leverkusen,

www.bayermaterialscience.com

[email protected]

10

page 1 of 11File No. PCS-1141e, replaces issue of 2008/02/25

Edition 2008-07-14 Technical Information

The Injection Molding of High-Quality Molded Parts –Preparing the Material: Drying • Injection molding

Why is drying necessary?

The correct drying of plastics saves waste, disruptionsto production and complaints. Moisture in and on thegranules evaporates at the temperatures that prevailduring processing and forms surface streaks and,in some cases, bubbles in the molded parts andsemi-finished products. This will generally not be assevere as the examples shown in Fig. 1. In the case ofplastics that are sensitive to hydrolysis, degradationof the molecular chains will also occur, causing adeterioration in the mechanical properties.

Fig. 1: Molded part in materialprocessed while moist.

With a lower level of moisture and a higher flowresistance as the injection mold is being filled, it ispossible for the escape of gas from the melt to beimpeded. The molded part is then defect-free on theoutside. Despite this, the material may have still beendamaged through degradation, causing the part toundergo premature failure in use, such as throughbrittle fracture (Fig. 2). If this fault is not noticed, veryexpensive complaints will generally result.

Figure 3 shows the development of faults (which canoccur in parallel) and offers drying as a remedy.In fact, adequate drying is indeed the only wayto avoid the faults referred to above, together with

the associated waste, disruptions to production andcomplaints.

Fig. 2: Brittle fracture on a part madeof hydrolytically degraded material.

Fig. 3: Fault development duringthe processing of moist material.

The different chemical structures of BayerMaterialScience´s thermoplastics and resultantsensitivity to hydrolysis lead to the following productclassification in terms of the faults that can beexpected if the material is processed in the moist state(Fig. 4).

11



Fig. 4: Faults caused by processing moist materials.

Figure 5 shows the two fundamental approaches todrying. Details will first be given of "solids drying", i.e.the drying of the granules prior to processing. Dryingthe melt by means of vented plasticization will becovered separately. The following types of dryers areused to dry plastics:

- circulating air dryers (50 % fresh air)- high-speed dryers operating with fresh air- high-speed dryers with partially recirculated air- dry-air dryers- vacuum dryers

Dry-air dryers are generally used in central dryingunits.

Fig. 5: The two fundamentalapproaches to drying.

Figure 6 shows empirical values for drying conditionswhich give the required drying results for injection

molding, providing that the equipment is operatedcorrectly and is in perfect working order. Where arange is given, the lowest values are minimum values.The higher values are intended more for extrusion.

The table also shows that almost all BayerMaterialScience thermoplastics can be dried on all thedifferent drying units.

Vacuum or dry-air dryers are thus recommended forthese materials, although vacuum drying is only usedvery rarely in practice (due to the very low dryingcapacity, among other things).

12



Engineeringthermoplastic

Drying temperaturein °C

Drying time/ h

Circulating dryer(50 % fresh air)

Fresh air dryer Dry air dryer

Apec® 130 4 to 12 2 to 4 2 to 3Bayblend®1)

Bayblend® FR1)100 to 1101)

85 to 1101) 4 to 8 2 to 6 2 to 5

Makrolon® 120 4 to 12 2 to 4 2 to 3Makroblend®

PC/PBTPC/PET

100 to 105110

4 to 124 to 12

2 to 42 to 4

2 to 42 to 4

1) Depending on the grade 10 °C below the Vicat VST/B120 temperature, but not higher as the recommended values.The above data apply to containers that have been stored at room temperature.In the event of stoppages lasting four hours or more, we recommend reducing the temperature of the dryer by 40 °C.

Fig. 6: Drying conditions.

Selecting a drying unit

The drying unit is therefore selected on the basis ofthe task in hand and the granule throughput rate.Drying cabinets are still in use today in cases wherethere are only small quantities of granules to be dried.On account of the low air-circulation rate in thesecabinets, the granule layer should not be more than3 cm deep if satisfactory drying results are to beattained within the specified times. Different types ofhigh-speed and fresh-air dryer are available.

Fig. 7: Drying cabinet.

All high-speed dryers have a high air throughputrate. This increases the danger of dust from the

surroundings being deposited on the granules via theair inlet, which is unfortunately a relatively frequentcause of faults on the molded part.

An intake filter can provide a remedy here and thisought to be cleaned at regular intervals. A cloggedfilter will reduce the air throughput and increase therequired drying time.

The air outlet should similarly be equipped with a filter.This will prevent any plastic dust in with the granulesfrom being blown into the surroundings. In the caseof glass fiber reinforced plastics, this dust can evencontain fine particles of glass.

Fig. 8: Operating principle of ahigh-speed dryer – air is sucked

through the granules from above.

13



Fig. 9: Hot-air dryer (PIOVAN, Munich).

Fig. 10: Operating principle of ahigh-speed dryer – air is blown through

the bed of granules from below.The measurement results in Fig. 11 show that, evenwith “high-speed dryers ”, the drying process cannotbe sped up at will. After the drying temperature hasbeen reached in the lower section of the bed ofgranules, it will take a further 70 minutes or so for thepermitted level of residual moisture to be achieved.It will then take the same amount of time again forthe granules to heat up to the drying temperature inthe upper section too and for drying to commencethere. It can also be seen from the curve that thematerial in the lower third of the granule containerwill be sufficiently dry after about two hours (see Fig.14 for the permitted moisture contents). As of thispoint in time, granules can be removed in portionsfor processing. If the amount of material required ismore than the container will hold at one go, then thegranules taken from below should be replaced with

fresh granules at the top. With automatic dryer andmachine feeds, this is best achieved with filling-levellimiters.

The size or drying capacity of the dryer to be usedshould be determined on the basis of the granulethroughput rate in each case. The rule of thumb is thatthe container should hold at least four times the hourlythroughput. An air flow of 2.2 to 3.0 m3/h per kilogramof granules to be dried will ensure that the granulesheat up sufficiently rapidly to the drying temperature.

Fig. 11: Drying process in a high-speeddryer operating with fresh air (example

of measured results for Makrolon®).

In very humid climates, drying cannot be conductedwith the dryers described so far. It is necessary touse dry-air dryers (Fig. 12) in these areas and –as already mentioned. The diagram of the operatingprinciple shows that the dry-air dryer is essentiallysimilar in design to the high-speed dryer. In the dry-airdryer, however, the air is predried with drying agentsbefore it enters the granule bed. This is generally doneby using two drying-agent batteries connected up inparallel, with one being regenerated while the otheris being used. The wide range of units of this typethat are available would suggest that this type of unitis gaining ground. This is no doubt due to the factthat the drying result is not affected by the ambienthumidity.

Apart from the intake filter for the fresh air, it is alsonecessary to filter the air coming from the granulecontainer in order to ensure that the drying agentis not soiled by either dust from outside or plasticdust from the granules. These filters similarly requireregular cleaning. It must also be ensured that the airis no hotter than 50 °C (operating temperature of thedrying agent) when it enters the particular battery thatis being used to dry the air. It may need to be cooled.

14



Fig. 12: Operating principle of a dry-air dryer.

Compressed air dryers operate using treatedcompressed air from the plant ’s own compressedair network. The compressed air is decompressedimmediately before the drying tank to bring the dewpoint down to values between minus 17 °C and minus40 °C (depending on how the compressed air ispretreated). As the systems are not energy-efficient inoperation, they are normally only used for drying smallquantities of material (up to approx. 25 kg/h). In mostcases the dryers are mounted directly on the machine.

Fig. 13: Compressed air dryer (style Montan).

The advantages of compressed air dryers are theeasy set-up and that drying agents are not necessaryanymore compared to dry-air dryers.

The residual moisture in the granules that is permittedfor injection molding varies according to the materialand is very low in some cases (Fig. 14). For extrusioneven higher degrees of drying can be necessary.

Engineeringthermoplastic

Permissible residualmoisture content inweight % (injectionmolding)

Apec® 1) 0.02Bayblend® 0.02Makrolon® 1) 2) 0.01 to 0.02Makroblend® 0.01

Fig. 14: Permitted residual moisture content forprocessing.

1) An adequate idea of dryness of Apec® and Makrolon® can beobtained by the TVI test.2) For Makrolon® 0.01 weight % applies for critical parts (ODS,optical parts).

Determining the residual moisture

The following measuring methods are used todetermine the moisture content of solid materials:

- Karl-Fischer-titration,- TVI test,- weighing with IR drying,- direct/indirect microwaves- carbide method.

The low moisture contents specified in Fig. 14can only be determined sufficiently accurately bysophisticated laboratory methods.

The following practical tests are also available,however, for establishing whether the material is toomoist.

TVI TestThe TVI test, which is very simple and can beconducted with a minimum of apparatus, works onlywith non-reinforced Makrolon® and Apec®. It can onlydistinguish between a sufficient degree of drying andan insufficient degree, however. The test essentially

15



involves a number of granules being heated on atemperature-controlled hotplate (for Makrolon®: 270±5 °C and for Apec® 310 ±5 °C) and then beingpressed flat between two glass microscope slides togive a diameter of approximately 1 cm. If there are nobubbles in the specimen after a further minute on thehotplate and subsequent cooling, then the granuleshave been sufficiently dried. Good drying results forMakrolon® and Apec® within the framework of thespecified drying conditions (temperature and time) arealso an indication of the fact that the dryer in questionis functioning correctly.

Fig. 15: TVI test unit.

Fig. 16: TVI test sample for Makrolon®.

Observing the melt strandDuring processing, moisture in the material manifestsitself through bubbles in the melt strand. With verymoist material, the melt strand will have a foamyappearance and a matt, streaky surface (Fig. 17).

Fig. 17: Appearance of the melt strandwith dry (left) and moist (right) material.

Partial filling of the moldMaterial that has been processed in the moist statealso reveals a foamy and streaky flow front with partialfilling of the mold. This constitutes a further means ofchecking that the material is sufficiently dry.

Fig. 17: Foamy flow front when the moldis partially filled with material that is being

processed in the moist state (left side).

Determining degradationThe degree of degradation that occurs in materialsthat are sensitive to hydrolysis when processed inthe moist state can be determined from viscositymeasurements, since the destruction of the moleculechains reduces the viscosity. To this end the solutionviscosity can be measured, or the familiar meltviscosity or melt mass-flow rate measurements canbe conducted. In all cases, the samples taken from themolded part should be carefully dried prior to testing.

16



Fig. 19: Determining the viscosity of solutions.

Fig. 20: Determining the viscosity of melts.

Drying faults

Drying faults have very simple causes in some casesand can generally be rectified by simple means. Thelist of the most frequent faults (Fig. 21) is designedto help locate and eliminate the cause as rapidlyas possible. As far as possible, all the faults shouldbe eliminated right from the start by means of aneffective quality assurance system. This table and theexplanations that follow also provide assistance here.

Fault 1:The drying conditions given for the individual plasticswill, of course, only lead to a satisfactory result if thetemperatures specified (setpoint temperatures) areactually attained in the granule bed.Whether the dryer is supplying the requisite heatingcapacity in general terms can normally be establishedby whether the controller switches at the setpointtemperature or not. In cases of doubt, an attempt mustbe made to place an additional temperature sensor inthe granule container.Controller deviations and excessive controlfluctuations are generally caused by the incorrectpositioning of the sensor, an insufficiently sensitivecontroller and/or poor coordination of the controlcircuit. An excessively high heating capacity can alsolead to greater control deviations. Excessively hightemperature peaks damage the material or lead to theformation of lumps. The best way to detect controlfluctuations and achieve the optimum control circuitsetting is by recording the temperature profile for awhile. A simple point recorder will suffice for this.The installation of better controllers can similarlymake a key contribution towards quality assuranceand save money by eliminating fault sources. Theapplication of an acoustic and/or optical sensorelement for notifying malfunctions in the dryer will alsoserve this same purpose.

Fault 2:If the dryer is operating at reduced efficiency, thenthis will generally be due to clogged filters or tothe fan rotating in the wrong direction. Both thesecauses reduce the air flow capacity to such an extentthat a sufficient level of drying is no longer possible.A reduced air flow capacity in conjunction with anunfavorably positioned temperature sensor and anincorrect setting for the control circuit can lead to anexcessively high air temperature in the inflow zone ofthe granule bed at the same time.

Fault 3:The use of air filters has already been described andrecommended. If the container lid is missing, this willlead both to material soiling and to the release ofmaterial dust into the environment.

Fault 4:The recommended drying conditions (Fig. 6) applyto dryers of sufficiently large dimensions. On thesedryers too, the requisite drying time can be longer ifthe quantities removed are not replenished in time.

17



Fig. 21: Frequent faults during drying and their causes.

Fault 5:The old rule which states that the residence time ofthe dry, still-warm granules in the unheated hoppershould not exceed 30 minutes applies here too. Thistime can be extended by insulating or heating thehopper.

Lengthy distances from the dryer to the machinecause the granules to cool down a great deal. Thiscooling is speeded up still further through conveyancewith cold atmospheric air.

The granules also absorb moisture again, as afunction of the moisture content of this air. This canbe prevented by conveying the granules with hot dryair taken from the dryair dryer. This is doubtless afurther reason why dry-air dryers are currently gainingin popularity.

Fault 6:Insulating the granule holder on the dryer will helpsave energy.

If the machine hopper is insulated, it may be possibleto get by without heating it.

Fault 7:If the inflow of drying air is at too high a temperature,then the granules can cake together. A slight sinteringprocess will take place in the lower section of thegranule bed, which is promoted by the pressure of thegranule layers above it. In most cases, only the centralcore of the container contents remains free-flowing.The granule throughput rate is then too high there,and insufficiently dried material is sent for processing.

A rapid emergency solution is to reduce the filling levelin the dryer (after breaking up the sintered areas),although this inevitably reduces the drying capacity.

18



It is naturally better to eliminate the causes of theexcessively high air temperature in the inflow zone

Fault 8:A considerably longer drying time than that indicatedwill generally be avoided on account of the energy

costs and for capacity reasons. If prolonged dryingtimes do result, however, then color changes andpossibly slight material damage can be caused tomaterials that are susceptible to this.

Fig. 22: Special faults with dry-air dryers.

Fault 9:If more than one drying container is fed by a dry-airgenerator, as shown in Fig. 23, then the air flow willpreferentially follow the route of least resistance. Ifthere are no setting or control facilities available, thencare should be taken to ensure that an identical fillinglevel is achieved in all the drying containers. It is,of course, better if there is a means of aligning theairflow distribution with the aid of throttle valves andflow measurement units.

Fault 10:The return air should be cooled to the workingtemperature of the drying agent, i.e. to about 50 °C,before it flows through the drying-agent battery. It isimportant to observe the operating instructions.

Fault 11:The drying agent is gradually used up; it has a servicelife of 2 to 3 years and should be replaced in goodtime.

Fault 12:The drying agent can also "collapse". Leakage airflows develop, which reach the air circuit again without

being redried. The drying-agent containers shouldthus be topped up again from time to time.

Conclusion

Correct material drying and the maintenance andmonitoring of a sufficient degree of drying are vitalaspects of quality assurance for the production ofmolded parts and semifinished products.

In the case of injection molding, this drying isgenerally conducted in the form of solids drying priorto processing. In extrusion, use is frequently madeof melt drying, in the form of vented plastication.This is also possible with injection molding and isbeing successfully used in cases where conditions arefavorable.

Proper drying also makes a contribution towardsthe conservation of resources. It prevents rejects,production stoppages and complaints and thus makesproduction more cost-efficient. It is also impossibleto recycle material that has suffered hydrolyticdegradation as a result of being processed in themoist state.

19



Fig. 23: Several granule containers are fed hot air from one hot-air generator.

20



This information and our technical advice - whether verbal, in writing or by way of trials - are given in good faith but without warranty, and this alsoapplies where proprietary rights of third parties are involved. Our advice does not release you from the obligation to check its validity and to test ourproducts as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufacturedby you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our products are sold in accordancewith the current version of our General Conditions of Sale and Delivery.

* This is a developmental product. Further information, including amended or supplementary data on hazards associated with its use, may be compiledin the future. For this reason, no assurances are given as to type conformity, processability, long-term performance characteristics or other productionor application parameters. Therefore, the purchaser/user uses the product entirely at his own risk without having been given any warranty or guaranteeand agrees that the supplier shall not be liable for any damage, of whatever nature, arising out of such use.

Under the recommended processing conditions small quantities of decomposition product may be given off during processing.To preclude any risk tothe health and well-being of the machine operatives, tolerance limits for the work environment must be ensured by the provision of efficient exhaustventilation and fresh air at the workplace in accordance with the Safety Data Sheet. In order to prevent the partial decomposition of the polymer andthe generation of volatile decomposition products, the prescribed processing temperatures should not be substantially exceeded.

Editor: Global Innovations - PolycarbonatesBayer MaterialScience AGD-51368 Leverkusen, Germanywww.bayermaterialscience.depcs-info@bayermaterialscience.com

21

ANEXO 4: BANCO FOTOMÉTRICO

1. INSTRUCCIONES PLEIADES INSTRUMENTS ................................................................................... 2

2. RESULTADOS DE ENSAYOS DE VALEO ......................................................................................... 10

Multicells Systems for Production

2

3

Multicells Systems for Production

Multicells reduced photometric systems allow measurement and qualification of products according to different standards (SAE, ECE, China, Japan) on short distance through a lens. Thanks to these devices our customers can test and certify many different products.

Those equipment especially designed for production are set up in industrial environment of automotive lighting industry. They allow checking products integrity before and after resistance, mechanical, vibration, temperature tests and many others.

The software has also been designed for a very easy use.

Stand-alone system. Compact. High maximum load (25kg/55pounds). Large measurement range: 0.01 to 1500C for signaling and 0.01 to 450 lux for lighting. High photometric resolution. Thanks to their design, our devices are among the most compact on the market. Short measurement distance. Enclosed system avoiding straight light. Motorized rotating and vertical stages. Configurable number and position of cells. Different measurements modes. High quality and repeatability of the measurements. Instant measurement. No photometric room required. Easy to use software, allowing different kinds of measures,

with a large range of standards and products. Our devices allow tests and qualifications according to many

different standards: ECE, SAE, Japan… etc. High quality maintenance with our reliable, timely, cost effective

services for soft/hardware and our reactive after sales service. Reasonable price.

Our multicells systems for production have many assets :

4

Multicells Systems for Signaling MES_SP

Measurement cells 7 cells

Photometric range 0,01 to 1500 Candela

Photometric resolution 4 digits

Display frequency 1 Hz

Measurement Mode

Continuous

PWM

Blinking

Power Supply

One power supply: 25V/7A

Setting accuracy

1µV ±(0,05% FS) 0,01mA ±(0,2% FS)

Weight: 120Kg

Multicells System Signaling Size

Height: 1882 mm

Width: 648 mm

Length: 2618 mm

Power requirements 230V/50Hz/16A

PC requirements

Processor: DualCore 2.7 GHz

RAM: 2Go

Software: ALPES

Multicells system for signaling

characteristics:

MES_SP has been designed to control

all the signaling functions of rear

products: Day Running Light (DRL),

Turn, Tail, Stop…

This kind of equipment is compatible

with different technologies: LED

(continuous or PWM mode),

discharge lamp, Xenon technology…

The system is equipped with a

motorized stage to place the product

easily and safely.

5

Multicells System for Lighting MES_LP

Measurement cells 8 cells

Photometric range 0,01 to 450 lux

Photometric resolution

4 digits

Display frequency 1 Hz

Measurement Mode

Continuous

PWM

Power Supply

One power supply: 18V/20A

Setting accuracy

1µV ±(0,05% FS) / 0,01mA ±(0,2% FS) 10µV ±(0,1% FS) / 0,01mA ±(0,2% FS)

Weight: 120Kg

Multicells System Lighting Size

Height: 1882 mm

Width: 648 mm

Length: 2618 mm

Power requirements 230V/50Hz/16A

PC requirements

Processor: DualCore 2.7 GHz

RAM: 2Go

Software: ALPES

Multicells system for lighting

characteristics:

MES_LP has been designed to control

all the lighting functions of head

products: high beam, low beam…

This kind of equipment is compatible

with different technologies: LED

(continuous or PWM mode),

discharge lamp, Xenon technology…

As the MES_SP, the system is

equipped with a motorized stage to

place the product both: easily and

safely.

6

The ALPES Software

Thanks to years of experience in the field of automotive lighting certification, Pleiades

Instruments has developed a new version of its famous software ALPES, especially dedicated for the

production equipment. The software provides specific prior/after reports to check whether the

testing (mechanical, vibrating, temperature…) are not damaging for the products.

This version has been designed to meet

and solve usual issues of the testing in Automotive

Lighting industry.

Indeed, Pleiades Instruments’ software

department has developed an application which is both:

easier to use and more ergonomic with a specific Man-

Machine Interface (MMI).

Thus, it is far simpler for operators to detect problems on production lines and to

check the integrity of products.

ALPES (Automotive Lighting Photometric Equipment Software) is an application used for controlling and running the photometric systems manufactured by Pleiades Instruments. It offers a user friendly and simplified user interface for operators in production mode, or a fully customizable software for administrators and Research & Development users.

ALPES is used for all the systems sold by Pleiades Instruments: goniophotometer and multi-cells, and for different products: signaling and lighting.

This software allows a large spectrum of measurements for complex

analysis, production… A database of standards that can be tested is provided with the system. ALPES provides a report indicating if a measurement is conform to the standards.

The administrator mode allows the user to prepare the measurements and to calibrate the cells if necessary; then, the operator has just to start the measurement and to analyze results.

Updates are also regularly available online.

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Pleiades Instruments

4 Rue de la Sure 38600 Fontaine, FRANCE

Phone: +33 (0)4 27 19 45 57 Fax: +33 (0)4 27 19 45 51

[email protected] www.pleiades-instruments.com

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mailto:[email protected]

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March 2014 I 1Property of Valeo. Duplication prohibited

Confidential

March 2014

Property of Valeo. Duplication prohibited

Confidential

VW - Module MultiLEDInjection HB Collimators in MD Moldes

Pre-FDPR Test Series

Ana Belén Prieto, Q PTM


Confidential

VW - Module MultiLED - Injection HB Collimators in MD Moldes

Summary

o 19-12-16:Meeting in MD office (Leiria), with Joaquim Laúdo, Ana Belén Prieto, FranciscoServant, on FDPR and star of tests next day in the morning.

o 20-12-16:In MD Moldes (Vades) in the morning, the mould wasn´t finished so in the affternoonwith Pedro Rodrigues, Francisco Servant and Ana B. Prieto, different collimators withMakrolon material was injected, in ten diferent tests (K1 to K11).

These collimators was measurement with multiled dummy, when system wasstabilized after 30min.

o 21-12-16:In the morning, with the best parameters of day before, was injected other test series(K12 to K18)

These collimators was measurement with multiled dummy and K16 and K17 injectionwas the best tests.

In the afternoon, it was FDPR about 4 hours with good results (see FDPR-HBcollimators 201216 file).

The last injection of FDPR was measurement with multiled dummy, and with morehours of injection, the results are better.

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Confidential


20-12-2016: Test Series – Cavity 3. Measurement with dummy

Measurement:

Test K3 Cavity 4.

(Injection November 2016)

Martos 114,6 lx

MD Moldes

(Vades)

110 lx

(-4,6lx )

Cavity 3. (lx) K1 K2 K3 K4 K5 K7 K8 K9 K10 K11

Part 1 101 102 102 96 102 95,7 96,7 98 99,2 97,4

Part 2 101 103 104 100 103

Part 3 101

Best tests: K1-K2-K3-K5


Confidential


Measurement:

Test K3 Cavity 4.


Martos 114,6 lx

MD Moldes

(Vades)

105 lx

(-9,6lx )

Cavity 3. (lx) K1 K2 K3 K4 K5 K7 K8 K9 K10 K11

Part 1 100 (-2) 93 (-3) 96

Part 2 100 (-4) 98 (-2) 96

21-12-2016: Same Parts previus day–Cavity 3. Measurement with dummy

Similary measurement that before day but with -3 lux aprox.

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Confidential

VW - Module MultiLED21-12-2016: New tests –Measurement with dummy all cavities

(lx) 1 2 3 4 1. 2. 3. 4.

K12(2 injections)

99,8 107 97,3 104 98,6 104 101 105

105 103

K13 98,2 106

K14 106

K15 106

K16 (2 injections)

104 109 103 106 104 107 105 108

102 109 103 107 103 108 105 109

Similary to K16 110 108 109

K17 101 108 106

K18 99,5 97,1

Last injection 107 111 106 110 106 109 108 110

Measurement:

Test K3 Cavity 4.


Martos 114,6 lx

MD Moldes

(Vades)

At the beginning: 105 lx

At the end: 107 lx


Confidential

VW - Module MultiLED

(lx) 1 2 3 4 1. 2. 3. 4.

K12(2 injections)

99,8 107 97,3 104 98,6 104 101 105

105 103

K13 98,2 106

K14 106

K15 106

K16 (2 injections)

101 99,3 103 106 104 107 105 108

102 10 103 107 103 108 105 109

Similary to K16 110 108 109

K17 101 108 106

K18 99,5 97,1

So FDPR begins with K16 parameters

Best test: K16 Best cavity: 2 Worst cavity: 3 (in all tests)

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Confidential

VW - Module MultiLED

21-12-2016 Measurement last injection with dummy all cavities

(lx) 1 2 3 4 1. 2. 3. 4.

FDPR

Last injection107 111 106 110 106 109 108 110

Measurement:

Test K3 Cavity 4.


Martos 114,6 lx

MD Moldes

(Vades)

At the beginning: 105 lx

At the end: 107 lx


Confidential

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Documents

ANEXO 1: CONTROL DE CALIDAD