PBT-BASF Ultradur B4406
To satisfy critical fire safety requirements in high-voltage microelectronics without compromising electrical insulation or physical finish, BASF’s Ultradur B4406 leverages an unreinforced, polybutylene terephthalate matrix with a specialized, migration-free flame retardant package. Boasting a density of 1.45 g/cm³ and a melt volume-flow rate of 19 cm³/10 min, this pure PBT grade achieves an outstanding UL 94 V-0 rating down to a thin-walled 0.4mm. Jucheng Precision, under ISO 9001 and IATF 16949 certified systems, excels in high-precision molding of Ultradur B4406. Using S136 stainless steel molds, we prevent corrosive outgassing wear, delivering flash-free, stable electronic connectors verified by Zeiss CMM.
Ultradur B4406 Migration-Free Fire Safety & Physical Modulus
Ultradur® B 4406 is an unreinforced, injection molding PBT grade engineered by BASF, formulated with non-migrating organic flame retardants to secure ultimate fire safety and dielectric strength under UL 94 standards:
| Flammability & Performance Standard | Ultradur B4406 Specification | Molding & Electrical Safety Advantage |
|---|---|---|
| Thin-Wall Flammability | UL 94 V-0 Rated at 0.40 mm | Achieves self-extinguishing safety in ultra-thin micro-connector geometries, preventing localized ignition and thermal propagation. |
| Migration-Free additive | Zero Halogen Surface Bloom | Prevents flame-retardant additives from blooming or migrating to part surfaces over time, ensuring clean surface aesthetics and stable contact resistance. |
| Material Density | Pure Density 1.45 g/cm³ | Heavy organic FR compound packages elevate the density of unreinforced matrix, providing enhanced structural weight feel and low porosity. |
Process & Thickness Configurations for Non-Migrating Ultradur B4406
With its high crystallization velocity and low melt viscosity, Ultradur B4406 processes beautifully inside precision tooling:
| Molding Process | Molding Compatibility & Operational Details |
|---|---|
| Thin-Wall Connector Modules | Excellent. Highly suitable for sub-millimeter plug-and-socket connectors, terminal grids, and intricate electrical relays with complex paths. |
| Precision Switch Bezels | Excellent. Its low molecular shrinkage supports stable dimensions in high-precision micro-switches, circuit breakers, and industrial sensor covers. |
| Dynamic Low-Moisture Sockets | Good. Extremely low water absorption prevents dimensional swelling in humid environments, ensuring tight-fitting snap assemblies. |
PBT-BASF Ultradur B4406 Tooling & Outgassing Matrix
Molding an unreinforced, flame-retardant grade like B4406 requires strict melt temperature windows to prevent outgassing corrosion, alongside desiccant drying:
S136 Hardened Steel Core (Corrosion Control)
At melt temperatures above 280°C, organic flame retardants in B4406 can break down, releasing corrosive acidic gases. Jucheng’s tooling division prevents cavity pitting by constructing molds with premium S136 stainless tool steel hardened to 48–52 HRC and machined on our 5-axis CNCs, ensuring long-term parting line precision.
High-Capacity Outgassing Slots
To prevent gas-induced diesel burn marks and short shots, we machine deep, strategically positioned venting channels (0.015mm to 0.020mm depending on gate layout) on the mold parting lines. This secures clean, blemish-free parts on multi-cavity runs.
Desiccant Drying Protocol (Hydrolysis Prevention)
PBT is highly sensitive to moisture at high melt temperatures. Wet molding results in rapid hydrolytic chain cleavage, causing severe splay, gas bubbles, and a major drop in impact strength. We desiccant dry Ultradur B4406 resin at 120°C (248°F) for 4 hours, keeping moisture strictly below 0.04%.
Melt & Mold Temperature Control
Processing barrel temperatures are maintained between 250°C and 275°C (482°F to 527°F) to ensure homogeneous melting. Mold temperatures are kept at 40°C to 70°C (104°F to 158°F) to optimize crystalline structure, high surface gloss, and mechanical strength.
Key Application Fields for PBT-BASF Ultradur B4406
- Smart-Grids & Electrical Infrastructure: High-insulation circuit breakers, smart electricity meters, terminal blocks, electrical relay housings, wall switch frames, and coil bobbins.
- EV Charging & Automotive Systems (IATF 16949): Electric vehicle charging gun housings, high-voltage junction box covers, interior fuse housings, and vehicle sensor housings.
- Consumer Electronics & Telecommunications: Wi-Fi router enclosures, charger adapter bodies, power tool housings, and set-top boxes.
Properties
| Density | 1.45 g/cm³ |
| Melt Volume-Flow Rate (MVR) (250°C/2.16kg) | 19 cm³/10min |
| Tensile Modulus | 3,000 MPa |
| Tensile Stress at Yield | 60 MPa |
| Tensile Elongation at Break (DAM) | 15 % |
| Flexural Strength | 90 MPa |
| Flexural Modulus | 3,000 MPa |
| Charpy Notched Impact Strength (23°C) | 3.5 kJ/m² |
| Melting Temperature (DSC) | 223 °C |
| Vicat Softening Point | 140 °C |
| Heat Deflection Temperature (HDT @ 0.45 MPa) | 140 °C |
| Heat Deflection Temperature (HDT @ 1.80 MPa) | 60 °C |
| Linear Mold Shrinkage (Parallel) | 1.30 - 1.60 % |
| Linear Mold Shrinkage (Normal) | 1.40 - 1.70 % |
| Flammability Rating (0.40mm - 3.00mm) | UL 94 V-0 Class |
| Flammability Rating (2.50mm) | UL 94 5VA Class |
| Maximum Part Size | 1000 x 800 mm |
| Minimum Part Size | 1 x 1 mm |