Design And Processing Options With TOPAS 5013
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This document proposes using TOPAS®5013 COC material to reduce the cost of optical lenses through injection molding. TOPAS®5013 has extremely high flowability, allowing the overall size of sprue runners and injection molding machines to be reduced. This provides advantages like halving material losses and improving productivity through shorter molding cycles and better part precision. Analysis found the runner size could be reduced 46% with TOPAS®5013 while maintaining filling pressure and dimensional precision of molded lenses. The document provides graphs and images comparing flow properties and molded parts between TOPAS®5013 and conventional COP materials.
![Overview
q Since TOPAS®5013 series has extremely high flowability…
n The overall size of sprue runner can be greatly reduced.
à For lenses with a higher sprue runner ratio, losses can be halved.
à It provides a significant advantage to optical parts for which no recycled material can be
used.
n Superior productivity (replicability) can be provided.
à Shape precision can be improved and mold work start-up can be shortened.
n Injection molding machine can be downsized.
à A one-size smaller molding machine can be used with an increased number of molded
product per shot.
n The molding cycle can be shortened.
à The small runner size can shorten the cooling time and molding cycle time.
Graph-2: Comparison TOPAS5013 vs COP
Graph-
Graph-1: Viscosity of TOPAS ®5013
Graph- （70mm2, 1mmt）
1mmt）
70
1000
250℃
60
260℃
270℃ 50
流動長 [m m ]
280℃
40
粘度( a･s)
COP
30 Cylinder Temp：280 degC
P
100 Mold Temp：120 deg C
20
TOPAS 5013
10 Cylinder Temp：270 degC
Mold Temp：120 degC
0
10 0 10 20 30 40 50 60
10 100 1000 10000 100000 Molding pressureP(MPa)
射出圧力 [M a]
せん断速度( (sec-1)
Share ratesec-1)](https://image.slidesharecdn.com/ppctopas5013runnerdesignforcocengmar-2007-120202201452-phpapp02/85/Design-And-Processing-Options-With-TOPAS-5013-2-320.jpg)
![Reference
Result of fluidity analysis （70mm2, 1mmt）
Fig-8
Fig-
Graph-3
Graph- Result of examination of flow length
70
60 Actual measurement value
50 Analysis value
流動長 [mm]
40
TOPAS 5013
30 Cylinder Temp: 270 deg C
Mold Temp: 120 deg C
20
10
0
0 5 10 15 20 25 30
射出圧力 [MPa]
n With reference to the flow length, it has been confirmed that superior accuracy can be provided.](https://image.slidesharecdn.com/ppctopas5013runnerdesignforcocengmar-2007-120202201452-phpapp02/85/Design-And-Processing-Options-With-TOPAS-5013-7-320.jpg)
![Notes
q Property values shown in this information include those actually measured at our
company or typical ones in accordance with various standards and testing
methods.
q Data in this technical information neither guarantees quality nor the results
evaluated by third parties
[Contact:]
l Polyplastics Co., Ltd.
TOPAS® Business Development Unit
TEL +81-3-6711-8615
FAX +81-3-6711-8617
E-mail: topas.info @ polyplastics.com](https://image.slidesharecdn.com/ppctopas5013runnerdesignforcocengmar-2007-120202201452-phpapp02/85/Design-And-Processing-Options-With-TOPAS-5013-8-320.jpg)
Design And Processing Options With TOPAS 5013
- 1. TOPAS®5013 Series TOPAS®5013 Series Proposal for Reduction in Optical Lens Cost by Proposal for Reduction in Optical Lens Cost by Using high-flowability COC Using high-flowability COC TOPAS® Cyclic Olefin Copolymer (COC) Your Clear Advantage in Optics Polyplastics Co. LTD. TOPAS Business Development Unit 27-Feb 2007 27-
- 2. Overview q Since TOPAS®5013 series has extremely high flowability… n The overall size of sprue runner can be greatly reduced. à For lenses with a higher sprue runner ratio, losses can be halved. à It provides a significant advantage to optical parts for which no recycled material can be used. n Superior productivity (replicability) can be provided. à Shape precision can be improved and mold work start-up can be shortened. n Injection molding machine can be downsized. à A one-size smaller molding machine can be used with an increased number of molded product per shot. n The molding cycle can be shortened. à The small runner size can shorten the cooling time and molding cycle time. Graph-2: Comparison TOPAS5013 vs COP Graph- Graph-1: Viscosity of TOPAS ®5013 Graph- （70mm2, 1mmt） 1mmt） 70 1000 250℃ 60 260℃ 270℃ 50 流動長 [m m ] 280℃ 40 粘度( a･s) COP 30 Cylinder Temp：280 degC P 100 Mold Temp：120 deg C 20 TOPAS 5013 10 Cylinder Temp：270 degC Mold Temp：120 degC 0 10 0 10 20 30 40 50 60 10 100 1000 10000 100000 Molding pressureP(MPa) 射出圧力 [M a] せん断速度( (sec-1) Share ratesec-1)
- 3. q Sample examination on molded lens à Precision of shape transcription was evaluated by 4 cavities lens mold (Lens dia.φ3.5) ・Fluidity was analyzed using MoldflowTM to examine the runner diameter; the operation was started in mode of φ2／φ5 switching. （4 cavity×2 pattern with common sprues） Fig-1 Result of analysis Fig- φ2 Φ5 Exclusively Conventional TOPAS® 5013 type COP Fig-3 Cavity layout Fig- COPキャビ Fig-2 φ3.5 Shape of Fig- aspherical lens
- 4. q Sample result of examination on a molded lens n The overall size of sprue runner was successfully reduced by 46% as a result of the combination of a φ2runner with TOPAS® 5013. (Runner weight 2.55g to 1.37g) à The filling pressure reduced 20% despite the small-diameter runner. à Lens with low level birefringence can be molded. Runner dia.φ2 Pic-3 Pic-4 TOPAS ® TOPAS ® 5013 5013 COP COP Runner dia.φ5 Φ3.5 molded lens
- 5. q Dimensional precision of molded lens à Even with the φ2 runner, TOPAS® 5013 was confirmed as relating excellent dimensional precision. Molding data (actually measured value) TOPAS® 5013 ＋exclusive designφ2 runner COP ＋ conventional design φ5 runner 1 shot weight：1.37g 1 shot weight：2.55g Filling pressure: 67MPa Filling pressure: 85MPa Fig-4 Fig- Fig-5 Fig- R1 face R1 face R2 face R2 face Sample result for lens surface precision measurement
- 6. q Design of TOPAS ® 5013 Mold à We will propose the runner size reduction by analyzing fluidity using MoldflowTM Ex) 3-D analysis model of lens Ex) cavity-filling pattern Fig-6 Fig- Fig-7 Fig-
- 7. Reference Result of fluidity analysis （70mm2, 1mmt） Fig-8 Fig- Graph-3 Graph- Result of examination of flow length 70 60 Actual measurement value 50 Analysis value 流動長 [mm] 40 TOPAS 5013 30 Cylinder Temp: 270 deg C Mold Temp: 120 deg C 20 10 0 0 5 10 15 20 25 30 射出圧力 [MPa] n With reference to the flow length, it has been confirmed that superior accuracy can be provided.
- 8. Notes q Property values shown in this information include those actually measured at our company or typical ones in accordance with various standards and testing methods. q Data in this technical information neither guarantees quality nor the results evaluated by third parties [Contact:] l Polyplastics Co., Ltd. TOPAS® Business Development Unit TEL +81-3-6711-8615 FAX +81-3-6711-8617 E-mail: topas.info @ polyplastics.com