難燃性（FR）

Flame Retardant (FR) resins—including UL 94 V-0, V-1, and 5VA-rated modifications of PC, PC/ABS, ABS, and PA66—are critical for electrical and electronic assemblies requiring strict fire safety compliance [1, 2]. However, processing FR polymers introduces serious manufacturing challenges: thermal instability (where FR additives degrade into highly corrosive gases), splay on aesthetic surfaces, and reduced melt flow. At Jucheng Precision, an ISO 9001 and IATF 16949 certified manufacturer, we mitigate these risks using premium corrosion-resistant S136 or M340 stainless mold steels, highly ventilated venting designs, and strict scientific molding temperature windows. We provide a comprehensive, free DFM analysis within 24 hours to prevent air traps and optimize gas venting, ensuring zero-defect electrical parts verified by Zeiss CMM inspection.

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Precision-injection-molded-flame-retardant-grey-PC-ABS-battery-brackets-and-electronic-housings-1

利用可能な材料

High-precision-injection-molded-black-PA66-GF30-engine-coolant-manifolds-and-bobbins-made-of-BASF-Ultramid-A3EG6

PA-BASF Ultramid A3EG6

現代のエンジンルーム内で継続的な熱劣化と高い繰り返し荷重を受けるには、極めて高い耐熱老化性が必要であり、BASFのUltramid A3EG6は、30%ガラス繊維強化、熱安定化ポリアミド66マトリックスによりそれを実現します。乾燥状態（DAM）での引張強度175 MPa、熱変形温度（HDT）250°Cを誇るこの高性能ナイロングレードは、熱サイクルを受ける高負荷構造部品向けに設計されています。IATF 16949およびISO 9001認証を取得したメーカーであるJucheng Precisionでは、Ultramid A3EG6の高応力成形を専門としています。社内の5軸CNC加工によるH13金型を活用し、繊維配向応力を軽減し、結晶化を最適化して、Zeiss CMM検査で検証された構造的に健全な部品を提供します。.

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Precision-injection-molded-black-Lexan-940A-flame-retardant-PC-electrical-casings

PC-SABIC Lexan 940A

複雑な電子機器ハウジングにおいて、機械的な落下靭性を損なうことなく、信頼性の高い構造用難燃性と優れた誘電絶縁性を確保するには、優れた材料が必要です。SABICのLEXAN™ 940Aは、非強化・中粘度の難燃性ポリカーボネートマトリックスを通じてこれを実現します。密度1.21 g/cm³、ガラス転移温度（Tg）150°Cを特徴とするこの非晶性グレードは、1.0mmでUL 94 V-0、3.0mmで5VAの優れた難燃性評価を達成しています。Jucheng Precisionは、厳格なIATF 16949およびISO 9001フレームワークの下で、Lexan 940Aの精密射出成形を専門としています。35台以上の先進的なプレス機と社内5軸CNC加工金型を擁し、その低い等方性収縮率（0.5%-0.7%）を制御し、Zeiss CMMによって検証された完璧な電気エンクロージャを提供します。.

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Molded-grey-Bayblend-FR3010-PC-ABS-flame-retardant-smart-meter-casings

Bayblend FR3010 PC/ABS for Custom Injection Molding

Covestro Bayblend FR3010 is a flame-retardant PC/ABS grade used in injection molding. Covestro lists UL 94 V-0 at 1.5 mm, 5VB at 2.0 mm and 5VA at 3.0 mm on material test specimens. For a custom molded housing, share the drawing, color, wall thickness, quantity and finished-part acceptance requirements. Material data helps screen a grade; it does not guarantee the performance or certification of a finished part.

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Common Flame Retardant (FR) Grades We Mold

We process high-performance halogen-free and eco-compliant Flame Retardant resins from global compounders, meeting strict UL 94 V-0 to 5VA certifications:

FR Material Class 代表的なブランド＆グレード 主な特性と利点
FR-PC/ABS Alloys
(Flame Retardant)		 • Covestro Bayblend FR3010
• Sabic Cycoloy CY6110 / CY6414		 Halogen-free flame retardant with an excellent balance of impact strength, flowability, and dimensional stability. Rated UL 94 V-0 at thin walls. Perfect for charger adapters, battery brackets, and smart meter housings.
FR-PC
(Flame Retardant)		 • サビック レキサン 940A / 943A
• 帝人 パンライト LN-1250G		 High-heat flame retardant with glass-like transparency options or opaque structural reinforcement. Exceptional dielectric properties. Applied in power switches, public transit brackets, and optical diffusers.
FR-ABS
(Flame Retardant)		 • Chi Mei POLYLAC PA-765 / PA-765A
• LG ABS AF312		 Cost-effective flame retardant with good impact strength, high surface gloss, and easy colorability. Widely used for office copiers, monitor casings, and home appliance housings.
FR-PA66 (Halogen-Free)
(Flame Retardant)		 • BASF Ultramid A3U42G6 ( Halogen-Free GF)
• DuPont Zytel FR50		 Environmentally friendly, halogen-free flame retardancy combined with high mechanical stiffness and thermal stability. Crucial for electrical circuit breakers, industrial terminal blocks, and EV fuse boxes.

Applicable Molding Processes for FR Resins

Due to FR resins’ low thermal stability and acidic emissions, specific molding processes must be implemented:

成形プロセス プロセス適合性と用途
標準射出成形 Excellent. Highly suitable for molding home appliance enclosures, consumer electronics covers, and terminal block housings.
薄肉成形 High. Ideal for high-density, thin-walled multi-pin electrical connectors and wall switches with rapid cycle times.
インサート成形 Excellent. Extensively used in smart grids to encapsulate conductive copper terminals and metal strips directly inside the FR housings.

Flame Retardant (FR) Plastic Molding Technical Guide

Processing FR resins requires strict thermal boundaries and advanced outgassing solutions to protect mold integrity and product aesthetics:

  • Corrosion-Resistant Steel selection: At high melt temperatures, FR additives degrade, releasing highly corrosive acidic gases (such as halogen or phosphorus acids). Jucheng’s in-house tooling division prevents tool degradation by using high-chromium corrosion-resistant steel (such as S136 or Bohler M340 hardened to 48–52 HRC).
  • Meticulous Pre-Drying: Wet FR resins are highly susceptible to accelerated thermal degradation, resulting in splay, dark spots, and polymer chain fracturing. We desiccant dry resins at 80°C–120°C (depending on substrate) for 3–4 hours to keep moisture strictly below 0.02%.
  • Tight Melt Temperature Windows: Melt temperatures must be strictly managed (e.g., keeping FR-PC/ABS below 250°C) and residency time in the barrel minimized to prevent active flame retardant compounds from breaking down.
  • 高換気ベント設計： Outgassing from FR resins can cause dynamic air trapping and diesel burn marks. Our toolmakers machine deep, strategically positioned venting channels (0.015mm to 0.020mm depending on material) on parting lines to secure clean, defect-free parts.

Key Application Industries for Molded FR Components

  • Electrical Infrastructure & Smart-Grid: Circuit breakers, wall switches, socket frames, relay housings, high-voltage connector housings, and smart electricity meters.
  • EV Battery Systems & Automotive (IATF 16949): 電気自動車のリチウムイオン電池ブラケット、セルホルダー、電気ヒューズボックスカバー、高電圧バスバー絶縁体、およびワイヤーハーネスシールド。.
  • 民生用電子機器・通信： Wi-Fi router enclosures, charger adapter bodies, power tool housings, dynamic power supply covers, and set-top boxes.
  • Office Equipment & Home Appliances: High-end copier housings, desktop printer casings, microwave control frames, and coffee maker structural bases.

材料特性

密度 1.18 - 1.22 g/cm³
Melt Mass-Flow Rate (MFR) (260°C/5.0kg) 12 - 25 g/10 min
降伏点引張強度 55 - 65 MPa
曲げ弾性率 2,400 - 2,800 MPa
アイゾット衝撃強さ（ノッチ付き、23°C） 400 - 550 J/m
ロックウェル硬度（Rスケール） 110 - 118 -
Flammability Rating (1.5mm - 3.0mm) UL 94 V-0 クラス
Glow Wire Flammability Index (GWFI @ 2.0mm) 960 °C
熱変形温度（HDT @ 1.8 MPa） 85 - 95 °C
線形成形収縮率 0.45 - 0.65 %
絶縁耐力 22 - 28 kV/mm
体積抵抗率 1.0E+16 Ω·cm
最大部品サイズ 1000 x 800 mm
最小部品サイズ 1 x 1 mm