A Range of Materials with Excellent Dimensional Accuracy for Communications Equipment and Sensor Components

Communications devices and sensor components used in technologies such as 5G communication and autonomous driving require dimensional accuracy, which requires resin materials that have a low level of warpage. To that end, Toray has now developed PBT and PPS resins with reduced warpage, which is one of the challenges faced by crystalline engineering plastics.

Features

In order to ensure dimensional accuracy, components used in 5G communication and autonomous driving, such as data communications devices, cameras, millimeter wave radars and LiDAR, tend to require materials with low warpage as a basic characteristic.
For such applications, Toray has developed TORAYCON™, a PBT resin based on low-warpage material, with the addition of hydrolysis resistance and flame retardancy properties, and TORELINA™, a PPS resin which boasts low warpage and excellent heat-cycle resistance.

1. TORAYCON™ Low-Warpage PBT Resin

We have achieved low warpage by alloying with amorphous polymers and selecting filler types in order to suppress warpage.
Compared with ordinary PBT resin, we have developed materials with further reduced warpage, including the 7151G-30 with significantly reduced warpage, the hydrolysis-resistant 7151G-X04, and the flame-retardant and hydrolysis resistant 7164G-X02.

Table 1. A Range of low warpage grades of TORAYCON™ and each features

Grade7151G-307164G-X027151G-F037151G-X04
Low warpage
Hydrolysis
resistance
  
High fluidity  
Flame retardancy   

Figure 1: Deformation in low-warpage grade TORAYCON™

2. TORELINA™ Low-Warpage PPS Resin

With TORELINA™, we have developed A575W20, which offers low warpage by alloying with special polymers and selecting a reinforcing filler in order to reduce the linear expansion coefficient in the machine direction (MD) and transverse direction (TD). We have also developed A695SW1, which has further improved low warpage and low linear expansion.For ADAS applications, TORELINA™ PPS resin is used in components that require a set temperature range and low hygroscopicity.

Figure 2: Warpage deformation in TORELINA™ A575W20 and A695SW1

When applying the above materials to each part, CAE analysis can be used to check for warpage and provide suggestions for optimizing gate placement,and also for analyzing glass fiber orientation.

Application Examples

  • General use in vehicle interiors (in conditions up to 85°C)
    TORAYCON™ 7151G-30
  • Harsh conditions inside vehicle engine compartments
    (up to 120°C)
    TORAYCON™ 7151G-X04
  • High-temperature conditions (up to 150°C)
    TORELINA™ A575W20
  • Compliance with communications device standards
    (including changing IEC standards)
    TORAYCON™ 7164G-X02
  • Ultra-low warpage applications and metal alternative
    TORELINA™ A695SW1

Consider using TORAYCON™ and TORELINA™ for a wide range of automotive-related components.
We will continue to develop materials that meet the needs of the market.