1) Screw characteristics Figures 54-56 show the diameter, breakdown torque and breakdown strength of a class three tapping

screw. (A value of 480 MPa is used as the tensile breakdown strength of the screw material.)

Figure 54: Relationship between nominal diameter and screw diameter (Class 3 tapping screw)

Figure 56: Relationship between screw nominal diameter and breakdown torque

Figure 55: Relationship between screw nominal diameter and breakdown torque

Figure 57: Relationship between tightening torque and axial force

The relationship between the screw tightening torque T and the axial force that acts on the screw can be expressed as follows: Formula (1) T=F{d2(1.15S+tan)+dww} Whereas:

s: Coefficient of friction at the screw surface tan:P/d2 P: Pitch dw: Equivalence coefficient of the frictional torque at the bolt head or nut seating face 1.30 d w :Coefficient of torque Assuming s = w = 0.25, Figure 57 shows the results from calculating the relationship between T and F for M2, M2.6 and M3 screws.
Basic values for use in calculations Nominal M2 M2.6 M3 d (mm) 1.98 2.58 2.98 P (mm) 0.4 0.45 0.5 d2 (mm) 1.740 2.308 2.675

The above is a summary based on the JSME Mechanical Engineers' Handbook published by the Japan Society of Mechanical Engineers
(2) Design of resin boss sections In addition to considering screw shape as set forth in section (1), it is necessary to design a resin boss section capable of enabling the screw to exhibit strength sufficiently. Starting hole diameter The starting hole size should be the same as or slightly smaller than the effective diameter and slightly larger than the root diameter shown in Figure 67; about 85% of the screw's nominal diameter is appropriate. If the starting hole is too large, it will damage the female thread of the resin boss section when the screw is tightened. If too small, the resin boss or the screw itself may become damaged. 2. Boss outside diameter A standard size for the outside diameter of the boss is about 2.5 times the nominal diameter of the screw. If the boss outside diameter is too small, the insufficient thickness could lead to such molding defects as short shot welds and the like. Alternatively, a small outside diameter could make the boss section susceptible to breaking in the vertical or lateral directions. 3. Depth A depth that is 2.5 times the nominal diameter of the screw is standard. If the screwing depth is too short, it could damage the resin female threads. 4. Plate thickness Use a plate thickness equivalent to the nominal diameter of the screw. If strength is insufficient, optimize the radii of the corners or add ribs for reinforcement. (For reference) 1.

Figure 58: Relationship between boss outside diameter Do and (vertical) stress generated 1. Boss outside diameter Do Tightening a screw leads to vertical and lateral stress working on a boss section a) Vertical breaking Use the following formulas to calculate. Formula (1) W = F (/cos+tan) Formula (2) = 3W (Do+Di)2/ (2Hdo (Do-Di)2) Whereas: Do: Outside diameter Di: Inside diameter F: Screw axial force : Coefficient of friction between the resin and the screw (assume 0.25) : Screw thread ridge angle 30 tan:P (Pitch)/D2 D2: Screw effective diameter H: Screw penetration depth For an M3 screw, assume Di = 2.57mm and H = 7.5 mm. Use 2,400 N for the strength of the M3 screw itself. With this, calculate the relationship between Do and the stress generated . The results are shown in Figure 58. To keep the stress generated below 100 MPa, Do should be at least 7 mm. b) Lateral breaking

Figure 59: Relationship between boss outside diameter Do and (lateral) stress generated Similarly, lateral breaking can be calculated using the following formula. Formula (3) = 4F/ ( (Do2-Di2)) Figure 59 show the calculation results. To keep the (lateral) stress generated below 100 MPa, Do should be at least 6 mm.

Figure 60: Relationship between screw effective length and drawing strength 2. Starting hole depth and screw effective length H If H is too shallow, it could damage the female threads of the boss section. The shear stress n that is generated at the base of the female thread ridges can be calculated using the following formula. Formula (4) n = F/ (ZDkP) Whereas: Z: Number of screw threads H/P (Pitch) k: A value of 0.75-0.88 for a triangular thread D = (D2+D1)/2 D2: Effective diameter D1: Root diameter Assuming k = 0.82 and n = 66 MPa, the results of calculating the relationship between H and screw drawing strength are shown in Figure 60 (for an M3 screw). With an effective depth of at least 6 mm, the drawing strength will surpass the strength of the screw itself (2,400 N). Note that the tip of a tapping screw includes 3-4 tapered threads that do not contribute significantly to fastening, so make sure to add to the starting hole depth of the boss section to account for the tapered section. 3. Boss mount plate thickness t Calculate using the following formula. Formula (5) = F/ ( (Do-Di)t) Similarly, using = 66 MPa and F = 2400N to calculate obtains a value of t = 2.35 mm. Therefore, a plate thickness of at least 2.35 mm is preferable when using an M3 screw. (3) Test examples 1. Bore a 4.5 starting hole into a 6-mm thickness square plate and tighten an M6 screw using 4 N m of torque. Then, subject the sample to 10 cycles of a heat cycle test using the following conditions and measure the loosening torque. (200C 30 minroom temperature 30 min) A504 and A310MX04 both have a loosening torque of 1 Nm. Subjecting the sample to temperature of Tg (93C) or higher results in lower loosening torque. Preannealing does not have a significant effect. A metal insert is recommended for applications requiring a large value for loosening torque. 2. On an A504 and A310MX04 3-mm thickness square plate, using 0.4 N m tightening torque on an M2 tapping screw in a 1.8-mm starting hole leads to female thread damage. Meanwhile, repeated tightening and loosening of screws in 1.5-mm and

Ultrasonic welding

1.6-mm starting holes leads to damage on the Phillips head of the screws. Using an M2.6 tapping screw in a 2.0-mm starting hole and repeating ten cycles of tightening and loosing at 0.5 N m torque results in a loosening torque of 0.35-0.45 N m.

Figure 61: Representative design of a welding section TORELINA* possesses superb heat resistance. Unfortunately, there is no heat-resistant adhesive that can take full advantage of TORELINA*'s excellent heat resistance. For that reason, ultrasonic welding is used in many applications requiring adhesion. In designing the weld section, as is the case with other crystalline polymers, avoid abutment; used shared joints instead (see Figure 61). In setting ultrasonic welding conditions, use a horn to concentrate a high degree of energy on the welding section and form a weld within a short period of time. If the horn pressure and amplitude are too small, welding defects will result. If too large, cracking may arise in the welding section or other areas susceptible to stress strain. Figure 62 shows welding results using an A504 test piece.

Figure 62: Relationship between ultrasonic welding conditions and welding strength <Welding conditions> Device: Branson 8490Z Welding section area: 12.7 3 mm Amplitude: 60 m Pressure: 0.2 MPa

Adhesion

Because of its high crystallinity, TORELINA* does not adhere well. Epoxy, cyanoacrylate, silicone and polyimide adhesives are used commonly. Give careful consideration, however, before using any of these as a structural adhesive.

Figure 63: Relationship between room temperature curing time and adhesive strength Test materials: A504/aluminum Adhesive: Toray epoxy paste TE2111 (Test example 1) A room temperature curing epoxy adhesive (Toray TE2111) was used in the test. The materials to be bonded were A504 and aluminum. Both materials were treated with sandpaper to create a rougher bonding surface. After removing oils with solvent, the adhesive was applied. The relationship between room temperature curing time and adhesive strength is shown in Figure 63. After five days at room temperature, adhesive strength reached saturation, exhibiting a value of more than 7 MPa. Table 15 shows a comparison between adhesive strength after and without heat cycling. The samples were allowed to harden for one hour at 100C. Other conditions match those used in Figure 63. Note that the sample subjected to heat cycling maintained comparable adhesive strength. See Table 15 for details. Table 15: Change in adhesive strength resulting from heat cycling (tensile shear)

Treatment Without treatment Heat cycling*

Adhesive strength (MPa) 7 9

* : 10 cycles, where 1 cycle = -35C (2 hours) room temperature (2 hours) 125C (2 hours)

Table 16: Test results using epoxy adhesive TE2101 (tensile shear) Adhesive strength (MPa) Materials bonded Blank 80C After heat

cycling* A504/A504 A504/aluminum A504/brass 5 7 6.5 1 6.8

(Test example 2) Toray room temperature curing epoxy adhesive TE2101 was used in a test. As in test example 1, the surfaces of the test specimens were treated with sandpaper. After removing oils with solvent, the adhesive was applied to the bonding surfaces. The curing conditions were one hour at 100C. The results are shown in Table 16. * : 10 cycles, where 1 cycle = -35C (2 hours) room temperature (2 hours) 125C (2 hours)

Table 17: Test results using high-temperature curing epoxy adhesive (tensile shear) Adhesive strength (MPa) Grade Blank A504 A310MX04 A310E A400MX01 1.5 1.3 3.2 1.2 After heat treatment* 3.2 1.3

(Test example 3) This test used high temperature curing epoxy adhesive. After removing oils from the surfaces of the test specimens using methanol, the adhesive was applied. Curing conditions were two hours at 140C. The results are shown in Table 17. Compared to A504 and A310MX04, A310E adheres well using an epoxy adhesive. *Heat treatment = 5 hours at 120C

Table 18: Test results from silicone bonding areas (tensile shear, A504) No annealing 2 175C2hrs 2.5 200C2hrs 2.7

(Test example 4) Silicone adhesive CY-233A/B (manufactured by Dow Corning Toray Silicone) was used in this test. The test specimens were annealed. Then oils were removed from the surfaces using methanol. The curing conditions were 30 minutes at 150C. The results are shown in Table 18. All bonds adhered well. When measuring the tensile shear strength, the adhesive itself exhibited cohesive failure. Annealing enhanced adhesive strength.

Table 19: Test results from silicon bonding areas (Tensile shear) Grade Adhesive strength (MPa) Location destroyed

A504 A310MX01

2.5 2.5

Bonding area Bonding area

(Test example 5) Silicon adhesive TSE322 (manufactured by Toshiba Silicone) was used in this test. The test specimens were cleaned using methanol. Then, the adhesive was applied and cured for 30 minutes at 150C. The results are shown in Table 19. All bonds adhered well.

Laser marking Recently, laser marking has begun replacing conventional ink marking in light of reliability and economic advantages. Lumonics laser marker model 930 was used to imprint laser markings on TORELINA*. The results are as follows.
1. 2. The markings are easily recognizable on products with black coloration, but difficult to recognize on products with white coloration. Among the different grades of TORELINA*, the laser markings were most easily recognizable on A310E, followed by A504 A515, with A310MX04 being the most difficult to recognize.