TO INCREASE PROCESSING EFFICIENCY, TO SAVE ENERGY AND PRODUCTION COSTS, AND TO INCREASE PRODUCT YIELD

LIMS (Liquid Injection Molding System) is a newly designed system, which includes a series of highly functional liquid silicone rubbers and an injection molding machine to precisely inject those fluids. From the set-up of raw materials to blending and molding, the entire process is automated to secure high quality products. Because the raw materials are liquid silicone rubbers, which exhibit excellent properties, they meet a wide range of requirements in the electrical, electronic, automotive and food industries. LIMS saves energy and increases productivity.

LIQUID SILICONE RUBBERS

High speed curing Long pot life Low viscosity Good release properties High tear strength

MOLDS
Cold-runner Flashless Runnerless

INJECTION MOLDING MACHINE

Accurate extruded amounts Stable shot

PUMPS
Metering with precision

EXCELLENT PROPERTIES
Liquid silicone rubbers are highly functional rubbers with heat resistance, electrical insulation, high strength, flame resistance and electric conductivity, and can produce not only transparent goods but also a wide variety of colored products.

AUTOMATING INJECTION MOLDING PROCESS

Good molding characteristics. Excellent release properties after curing. The entire Process can be automated.

NO ENVIRONMENTAL POLLUTION
The curing reaction produces no by-products. If flashless and runnerless molds are used, the treatment of cured waste materials are eliminated.

SAVING PROCESSING TIME

The curing of liquid silicone rubbers is an addition reaction. The curing speed is rapid, saving significant processing time.

INCREASING PRODUCT YIELD

Because the raw materials are liquid silicone rubbers, which can be injected at low pressure, they are suitable for molding precision parts. The components of A and B can be accurately blended at an accurate ratio, to secure high quality products.

LIMS are liquid silicone rubbers, which exhibit excellent heat resistance, electrical insulation, radiation resistance and corona resistance of conventional silicone rubbers. Shin-Etsu provides a number of LIMS grades for use in a wide range of applications such as general-purpose, high strength, transparent and flame resistant types. We continue to develop new products to meet specific requirements of our customers.

KE2000 Series
These products are highly transparent, high-strength and fast curing types of silicones, available in a range of hardnesses from 20 to 60. Because of molding with flashless and runnerless molds, automation with short cycle is possible.

KE1950 Series
These products are transparent and high-strength silicones, available in the range of hardnesses from 10 to 70.

General Properties
products Items Appearance Viscosity*
1

Fast curing, highly transparent, high strength KE2000-20 (AB) KE2000-30 (AB) Translucent Translucent 250 250 Transparent 1.10 32 8.9 670 25 5 2.0 10 KE2000-35 (AB) Translucent Translucent 500 500 Transparent 1.12 36 9.5 650 30 5 2.2 10 KE2000-40 (AB) Translucent Translucent 500 500 Transparent 1.12 42 9.2 600 30 6 2.1 10 KE2000-50 (AB) Translucent Translucent 1,000 1,000 Transparent 1.13 52 9.8 550 35 6 2.0 10 KE2000-60 (AB) Translucent Translucent 600 600 Transparent 1.14 60 9.6 460 35 8 1.9 10

Liquid A Liquid B Liquid A Liquid B

Translucent Translucent 180 180 Transparent 1.08 23 8.5 750 8.0 5 2.1 10

*1 Brookfield-type rotational viscometer

Before curing After curing *2 Before curing After curing*2

Appearance Specific gravity at 23C (73.4 F) Hardness, Durometer type A Tensile strength Elongation at break
Tear strength, crescent type

MPa % kN/m % % Tm

Compression set *3 Linear shrinkage Volume resistivity

products Items Appearance Viscosity*

1

Transparent, high strength KE1950-10 (AB) KE1950-20 (AB) Translucent Translucent 150 150 Transparent 1.10 20 6.4 900 25 15 2.1 10 KE1950-30 (AB) Translucent Translucent 250 250 Transparent 1.10 32 8.8 700 25 22 2.0 10 KE1950-35 (AB) Translucent Translucent 500 500 Transparent 1.12 36 9.8 700 30 36 2.2 10 KE1950-40 (AB) Translucent Translucent 480 480 Transparent 1.12 42 9.8 650 35 20 2.1 10 KE1950-50 (AB) Translucent Translucent 680 680 Transparent 1.13 52 9.3 550 40 28 2.0 10

Liquid A Liquid B Liquid A Liquid B

Translucent Translucent 60 60 Transparent 1.08 13 3.9 700 10 12 2.3 10

Pas Appearance

Specific gravity at 23C(73.4 F) Hardness, Durometer type A Tensile strength Elongation at break
Tear strength, crescent type

MPa % kN/m % % Tm

Compression set Linear shrinkage Volume resistivity

*2 5 minutes press-curing at 120C(248F)

1 hour post-curing at l50C(302F)

KE1990 Series
These products are general-purpose silicones, available in hardness of 40, 50, and 60. They are designed primarily for use in keypad applications. KE1990-40 meets the standards of UL 94HB, KE1990-50 and KE1990-60 are equivalents of UL 94HB.

KE2010(AB), KE2011 (AB), KE1995 (AB)

These products are oil resistant types, KE1995 is qualified under JIS B 2401 4 type C (O-rings).

PIGMENTS FOR COLORING LIMS SILICONE RUBBERS

The following pigments are for coloring LIMS materials, Oil-bleed pigments are also available.
PIGMENTS FOR OIL BLEED
Products Color

KE1955 (AB)
This product is a flame resistant silicone, it meets the standards of UL V-0.

PIGMENTS
Products Color

KE1935 (AB), KE 1987 (AB), KE 1988 (AB)

These materials are suitable for making highly transparent products.

LIMS Color-01 LIMS Color-03 LIMS Color-06

Black Reddish brown Brown

LIMS Color-02 LIMS Color-04 LIMS Color-05

Black Orange Grayish-green

*Please contact us for other colors of pigments. Highly transparent, high strength KE1950-60 (AB) Liquid A Liquid B Viscosity*1 Pas Appearance Specific gravity at 23C(73.4 F) Hardness, Durometer type A After curing*2 Before curing After curing*2 Tensile strength Elongation at break
Tear strength, crescent type

products Items Before curing Appearance

General purposes KE1990-40 (AB) Translucent Translucent 90 90 Translucent 1.12 39 6.5 380 6 9 2.0 5 KE1990-50 (AB) Translucent Translucent 60 60 Translucent 1.12 50 7.0 300 7 10 1.8 5 KE1990-60 (AB) Translucent Translucent 120 120 Translucent 1.15 60 7.0 250 8 10 1.8 5 Oil resistant KE1988 (AB) Translucent Translucent 600 450 Transparent 1.15 62 7.8 250 35 49 2.2 100 KE2010 (AB)*4 Gray Gray 800 800 Gray 1.23 50 8.5 450 20 10 1.8 50 KE2011 (AB) Gray Gray 1,000 1,000 Gray 1.21 50 8.5 450 25 10 1.8 50

Flame resistant KE1955 (AB) Black Black 700 700 Black 1.25 55 8.5 450 30 10 1.8 100

KE1950-70 (AB) Translucent Translucent 750 750 Transparent 1.15 70 7.8 350 40 50 2.1 10 Highly transparent

Translucent Translucent 730 740 Transparent 1.14 60 7.8 380 35 22 1.9 10

Liquid A Liquid B

MPa % kN/m % % Tm

Compression set Linear shrinkage Volume resistivity

products Items Appearance Viscosity* Pas Appearance Specific gravity at 23C(73.4 F) Hardness, Durometer type A Tensile strength Elongation at break
Tear strength, crescent type
1

KE1935 (AB) Liquid A Liquid B Liquid A Liquid B Transparent Transparent 80 45 Transparent 1.03 55 5.9 350 8.0 30 3.2 10

KE1987 (AB) Translucent Translucent 700 700 Transparent 1.15 55 8.3 430 35 50 2.1 100

KE1995 (AB) Reddish brawn Reddish brawn 400 400 Reddish brawn 1.59 72 5.9 110 5.0 9 1.9 50

MPa % kN/m % % Tm

Compression set Linear shrinkage Volume resistivity

*3 5 minutes press-curing at 120C(248F)

4 hours post-curing at 200C(392F)

*4 Oil bleed type

*5 According to JIS 6249 testing method (not specified values)

4

1. Curing Temperature Although the optimum curing temperature varies with the thickness and shape of the product, standard temperatures range from 130C (266F) to 200C (392F), but curing is possible at temperatures as low as 90C (194F) and as high as 210C (410F). 2. Injection Pressure Optimum results are obtained at a curing temperature of 130C (266F) - 200C (392F) , at pressure ranging from 40 kg/cm2 to 120 kg/cm2. 3. Curing Time Products can be molded in a very short cycle, no more than 10 seconds per millimeter thickness at 150C (302F). 4. Apparent Viscosity Apparent viscosity varies with shear rate, the relationship is indicated by a straight line on a logarithmic graph (please refer to Figure: Viscosity on page 6). 5. Linear Shrinkage Linear shrinkage ranges from 2% to 3% at temperatures between 100C (212F) to 150C (302F). (please refer to the table of General Properties on page 3-4). 6. Pot Life Pot life after mixing the components of A and B varies with temperatures. Typically, the viscosity remains constant for 72 hours at room temperature (25C (77F)). To extend the pot life, a chiller (a cooling device) set in the mixing section is recommended.

Curing Mechanism
Curing of liquid silicone rubber occurs by an addition reaction as illustrated below. The cure rate is accelerated when the materials are heated.
CH 3 OSi - CH = CH 2+ H - Si - CH 3 CH 3 CH 3 OSiCH 2CH 2Si - CH 3

CH 3

CH 3- Si - H + CH 2= CH - SiO CH 3 O CH 3 OSi - CH = CH 2+ H - Si - CH 3 CH 3

Pt CH 3

CH 3

O O

CH 3 CH 3

CH 3 - SiCH 2CH 2SiO OSi - CH 2 CH 2 - Si - CH 3 CH 3

VISCOSITY AND CURING CHARACTERISTICS OF KE2000 - 40 (AB)

Viscosity
10000 10
3

Pot Life vs. Viscosity

Common silicone KE951-U 25C (77F) 2 5 C (7 7 F ) 8000 25C (77F)

Viscosity(Pas)

10 2

Viscosity(Pas)

6000

4000

10 1

120C(248F) 150 C( 3 0 2 F )

2000 1 8 0 C( 3 2 6 F ) 1 10 2 0 10 3 Shear rate (1/sec)

Flow Tester : l.0 X 10 m m L

5C (41F )

10 4

4 days

10

Curing Characteristics
150C(302F)

Molding Temperature vs. Curing Time

1000

6.0 5.0 Torque (MPa) 4.0 3.0 2.0 1.0 0 0 0.5 1.0 1.5 Time : min. 2.0 2.5 1 2.0

Curing time (sec) (T10)

KE2000-40

100

KE 1950-40

10

2.2

2.4

2.6

2.8

1/T (X10-3 K-1)

Molding machines corresponding to viscosity ranges of liquid silicone rubbers (50 - 2,000 poise) at room temperature, should be used. Basically, the injection molding system includes a

quantitative delivery pump and a dynamic or static mixer. There are compact injection molding machines especially designed for high precision LIMS (Please contact Shin-Etsu for details).

Basic Design of LIMS Molding Machine

Metering discharge pump
Components A and B are metered accurately at a 1:1 ratio by a pressure pump and discharged.

Injector
Pressure and injection velocity are set (LIMS silicones can be molded at a very low injection pressure).

Material feeder pump

Pails (or drums) of components A and B are set and feed into the pump.

Mixer
The components are mixed thoroughly by a dynamic or static mixer, and injected by pressure directly into the mold.

Mold

Shut-off nozzle
A shut-off mechanism prevents material leaking from the nozzles.

P(Pigments):option

Mold closing
The closing and opening of the mold die are operated sequentially with the feeder pump, the metering pump and the injector.

ADVICE FOR SYSTEM DESIGN

Proper selection of seals for injection machinery is

essential to the ultimate performance of the system. For example, nitride steel or ceramics should be used for sliding or rotating contacts where there is a potential for metal-to-metal contact. To avoid seepage of materials, 1- 3 ply Teflon packing are recommended.

It is important that there are no dead spaces where

silicones can accumulate in the shut-off nozzles, clamps and molds after the mixing process occurs.

Liquid silicone rubbers are compressed liquids. Flow

control of each component is necessary when molding.

Because of the liquid nature of the raw materials, molds

voids should be tightly sealed to prevent leakage.

The mold should be equipped with at least one vent for

quick air release. Please contact us for the other details.

Abrasion resistant materials should be used for mechanical

parts (mixer and mold die) to avoid wear caused by the filler in liquid silicone rubbers.

MOLDING DEFECTS, CAUSES AND COUNTER-MEASURES

Defects

Causes
Incomplete curing Insufficient molding pressure Increase pressure

Countermeasures
Extend curing time and increase temperature

Blisters
Entrapped air Uneven heating Incomplete curing Vent the pails completely and adjust injection velocity Adjust heating unit Extend curing time Vent the pails completely Prevent air entrapment during injection Decrease temperature of metal mold, control temperature distribution of metal mold Adjust injection velocity, and check the mixer Adjust volume mixer and injection velocity Increase the pressure and decrease the temperature Decrease injection time Provide air vent Balance gate Extend curing time, increase temperature of metal mold Use polished metal mold with hard chromium plating and apply proper quantity of release agent. Extend curing time Repair metal mold Check the heating method Check nozzles Eliminate curing inhibition materials Check the mixing system

Voids Rough surfaces Uneven color

Insufficient air vent Entrapped air Excess temperature of metal mold Incomplete mixing Fluctuation in mixing ratio or incomplete mixing Improper molding pressure

Weld marks

Excess injection time Poor air vent at fused part Defective gate port Incomplete curing

Poor luster
Rough surface of metal mold Improper curing conditions

Poor mold releasing

Defective surface condition of metal mold Uneven distribution of surface temperature

Leakage from nozzles Incomplete curing

Wear and incision on nozzles Curing inhibition Improper mixing ratio

FOR GENERAL PURPOSES

Primer No. 4 Primer No. 4 is a general use primer, because of its low viscosity, it is easy to handle and has excellent drying property.
General properties of Primer No. 4 Product Appearance Viscosity Specific gravity Non-volatile matter Solvent Pot life Drying Primer No. 4 light yellow, transparent 0.2 - 1.0mm2/s 0.77 - 0.78 6 - 8% Ligroin 24 hours Air drying for l5 minutes

How to apply
Apply the primer to the metal either by brushing, dipping or spraying. Wait about 15 minutes at room temperature after the primer is applied. Pot life is 24 hours after the primer is applied.

FOR BONDING TO PLASTICS

Primer X-33-156-20 Premier X-33-156-20 is especially good for bonding to plastics, and it can either be air dried or oven baked.
The General Properties of Primer X-33-156-20 Product Appearance Viscosity Specific gravity Non-volatile matter Pot life Primer X-33-156-20 light yellow 0.2 - 1.0mm2/s 0.70 - 0.72 3 - 5% 24 hours

How to apply
It can be applied by either dipping, brushing or spraying. Primed inserts may be used after 30 minutes of air drying at room temperature. Adhesion is improved, if the inserts are baked in an oven at 80C(176F) - 120C(248F) for 10 - 20 minutes after 30 minutes of air drying. Pot life is 24 hours after the primer is applied. Containers should be kept in a cool and dark place. The solvent used as a diluent should be handled with caution.

Quality
1. Materials such as amines, sulfur, organic phosphorus compounds or organic tin compounds may cause curing inhibition of liquid silicone rubber. A preliminary curing test is recommended.

PACKING
Packing Products 18-liter can 18 kg KE2000-20(AB) KE2000-30(AB) KE2000-35(AB) KE2000-40(AB) KE2000-50(AB) KE2000-60(AB) KE1950-10(AB) KE1950-20(AB) 20 kg 180-liter drum 180 kg 200 kg

Materials that may cause curing inhibition.

Chloroprene and other synthetic rubbers Sulfur compounds Plasticized polyvinyl chloride resins Amine cured epoxy resins PVC insulating tapes Resin containing soldering fluxes

2. Liquid silicone rubbers should be stored in a cool and dark place, away from rain or humidity.

Safety Guide
1. When using LIMS materials in medical appliances or food equipment, users should confirm that they conform to appropriate regulations. 2. If LIMS materials contact the skin, wipe them off immediately and clean the area with soap. 3. If the materials get into eyes, wash them immediately with a large amount of water and see an eye doctor if necessary. 4. Contact of component B with alkali substance may cause the evolution of flammable hydrogen gas. Precautions should be taken to prevent this. 5. Please contact our sales division for material safety data sheets (MSDS).

KE1950-30(AB) KE1950-35(AB) KE1950-40(AB) KE1950-50(AB) KE1950-60(AB) KE1950-70(AB) KE1990-40(AB) KE1990-50(AB) KE1990-60(AB) KE1955(AB) KE1935(AB) KE1987(AB) KE1988(AB) KE2010(AB) KE2011(AB) KE1995(AB)

10

Silicone Division, Overseas Planning and Administration Department

6-1, Ohtemachi 2-chome, Chiyoda-ku, Tokyo, Japan Phone : +81-(0)3-3246-5171 Fax : +81-(0)3-3246-5363
Shin-Etsu Silicones of America, Inc.
1150 Damar Drive, Akron, OH 44305, U.S.A. Phone : +1-330-630-9860 Fax : +1-330-630-9855

Shin-Etsu Silicone Korea Co., Ltd.

International Insurance Bldg. 904, 120, 5-ka, Namdaemoon-ro, Chung-ku, Seoul, Korea Phone : +82-(0)2-775-9691 Fax : +82-(0)2-775-9690

Shincor Silicones, Inc.

1030 Evans Avenue, Akron, OH 44305, U.S.A. Phone : +1-330-630-9460 Fax : +1-330-630-1491

Shin-Etsu Singapore Pte. Ltd.

150 UBI Avenue 4, #03-00, Singapore 408825 Phone : +65-6743-7277 Fax : +65-6743-7477

Shin-Etsu Silicones Europe B. V.

Bolderweg 32, 1332 AV, Almere, The Netherlands Phone : +31-(0)36-5493170 Fax : +31-(0)36-5326459

Shin-Etsu Chemical Co., Ltd. Shanghai Liaison Office

2211 Shui On Plaza, 333 Huaihai Zhong Road, Shanghai, China Phone : +86-(0)21-5306-9966 Fax : +86-(0)21-5382-3970

Shin-Etsu Silicone Taiwan Co., Ltd.

7F, No.102, Civil Boulevard, Sec.4, Taipei, Taiwan R.O.C. Phone : +886-(0)2-2751-6999 Fax : +886-(0)2-2751-6769

The data and information presented in this catalog may not be relied upon to represent standard values. Shin-Etsu reserves the right to change such data and information, in whole or in part, in this catalog, including product performance standards and specifications without notice. Users are solely responsible for making preliminary tests to determine the suitability of products for their intended use. Statements concerning possible or suggested uses made herein may not be relied upon, or be construed, as a guaranty of no patent infringement. The silicone products described herein have been designed, manufactured and developed solely for general industrial use only; such silicone products are not designed for, intended for use as, or suitable for, medical, surgical or other particular purposes. Users have the sole responsibility and obligation to determine the suitability of the silicone products described herein for any application, to make preliminary tests, and to confirm the safety of such products for their use. Users must never use the silicone products described herein for the purpose of implantation into the human body and/or injection into humans. Users are solely responsible for exporting or importing the silicone products described herein, and complying with all applicable laws, regulations, and rules relating to the use of such products. Shin-Etsu recommends checking each pertinent countrys laws, regulations, and rules in advance, when exporting or importing, and before using, the products. Please contact Shin-Etsu before reproducing any part of this catalog. Copyright belongs to Shin-Etsu Chemical Co., Ltd.

JAB CEARTIFICATE No.R003

JAB CEARTIFICATE No.RE006

http://www.silicone.jp/
C Shin-Etsu 2000.2/2001.9 1 2.B.P. Printed in Japan.