dupont etpv web seminar - engpolymer.co.kr · dupont™ etpv and cross-linked rubbers astm d2000 /...

DuPont™ ETPV Web SeminarTHE THERMOPLASTIC RUBBER THAT RESISTS OIL AND HEAT

April, 2006

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DuPont™ ETPV Web Seminar

Sponsored by:

Mark Jacobson

DuPont™ ETPV Business Manager

DuPont™ ETPV Web SeminarTHE THERMOPLASTIC RUBBER THAT RESISTS OIL AND HEAT

The information and suggestions provided in this on-line seminar are based on data believed to bereliable, but the DuPont Company makes no warranties express or implied as to their accuracy andassumes no responsibility or liability arising out of its use by others. Further, the information andsuggestions are not intended to substitute for any testing you may need to conduct to determine foryourself the suitability of a particular material for a particular purpose. DuPont makes no guaranteeof results and assumes no obligation or liability in connection with the use of the information orsuggestions provided in this seminar.

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DuPont™ ETPV Web Seminar

Presented by:

Dan Saunders

North America Processing Specialist

Coreen Y. Lee

Development Specialist, Flexible Solutions Group

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Agenda

Why DuPont™ ETPV1

Product Line Portfolio and Key Properties2

Part Design Considerations3

Tool Design Considerations4

Processing Considerations5

Summary7

DuPont™ ETPV Applications6

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Why are you interested in DuPont™ ETPV?

Because replacing cross-linked rubberwith a thermoplastic material willsignificantly reduce costs.

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Why DuPont™ ETPV versus Thermoset Rubber

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Why DuPont™ ETPV versus Thermoset Rubber

Silicone Rubber DuPont™ ETPV Savings

No of cavities 4 4

Annual volume 1000000 1000000

Cost per machine hour 24 30

Density 1.15 1.08 g/cm2

Material price 10.80 11.52 USD/kg

Part net weight 10.0 9.4 grams

Waste 10.0 1.0 %

Part weight including waste 11.0 9.5 grams

Cycle time 90.0 20.0 70.0 sec

Usability 95.0 95.0 %

Time/usable part 23.7 5.3 18.4 sec

Shot weight excl sprue 44.0 37.9 6.1 grams

Production time/yr 6579 1462 5117 hours

Material cost per part 0.119 0.109 0.010 USD

Machine cost per part 0.158 0.044 0.114 USD

Material and Machine cost per part 0.277 0.153 0.124 USD

Annual M & M cost 276,695 153,129 123,565 USD

Savings 45 %

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DuPont™ ETPVengineering thermoplastic vulcanizates

The thermoplastic rubber that resists oil and heat

a high performance cross-linkedelastomer dispersed in a highperformance thermoplastic elastomer

Recycling code (ISO 11469) > AEM + TPC - ET <AEM = ethylene acrylic elastomerTPC - ET = thermoplastic ether ester elastomer

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DuPont™ ETPV and cross-linked rubbers

ASTM D2000 / SAE J200 Specifications.N.b. The purpose of this chart is to give a general overview. Formulation may affect compound performance.

Epichlorohydrine (ECO)

300

275

250

225

200

150

175

125

100

75

50

No req. 140% 120% 100% 80% 50% 30% 20% 10%

DuPont™ ETPVVamac®

Kalrez®

Viton®

Fluorosilicone

Polyacrylate (ACM )HNBR

Nitrile (NBR)

Silicone

EVA(high VA)

Ethylene-propylene

Butyl

SBR & NR

EPDM

Hypalon®

Neoprene

Swell in ASTM #3 Oil

Hea

tre

sist

ance

,°C

PU

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Agenda

Why DuPont™ ETPV





2

1

Summary7


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Product LineStandard grades

60A01L NC010 60 Shore A, lubricated

70A01 NC010 70 Shore A



95A02 NC010 95 Shore A for blow molding or extrusion

Heat stabilized grades

60A01HSL BK001 60 Shore A, lubricated

90A01HS BK001 90 Shore A

95A02HS BK001 95 Shore A for blow molding or extrusion

Concentrates

MB80L NC Lubrication MB, natural color

MB80L BK Lubrication MB, black

Hytrel® 40CB Black, add ~2%

Hytrel® 30HS Heat stabilizer MB, add ~ 5%

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Elongation@break - 50% Retention for DuPont™ ETPVAir Oven Aging

100

1000

10000

100000

120 130 140 150 160 170 180

Temperature (°C)

Tim

e(h

) 60AHS

60A

90AHS

90A

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ETPV 60A01 HSLETPV 60A01LETPV 90A01 HS

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ETPV 60A01 HSLETPV 60A01LETPV 90A01 HS

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Agenda

Why DuPont™ ETPV





1

3

Summary7


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Part Design—Flexural Seals

Anneal 1–4 hours at 150°C to reduce the compression set and improve elongation/strength15%

20%

60%

2.0%Flexure seal design(Lip thickness = 0.5mm)

5.6%4.5%Flexure seal design(Lip thickness = 1mm)

13.8%57.0%45.6%

Maximal strain inthe seal according

to the design

Compression sealdesign (O-ring)

23%95%76%Compression set at 150°

C/168 hSeal Design

ACM 60 Shore ADuPont™

ETPV90A01DuPont™

ETPV60A01

Mix of compression and tensile strain.Highest stress are located on small

areas (in the skin of the lip)

Mainly compression strain. Higheststress located on nearly all part

+13%

-10%

-58%

0%

Strain (%)

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Part Design—AdhesionDesign parts with mechanical locks supplemented by chemical adhesion

Adhesive failure Cohesive failure

*ISO 527-1 (1A tensile properties)

DuPontTM ETPV

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Agenda

Why DuPont™ ETPV





1

4

Summary7


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Tool Design—Ejection

Automatic ejection in a tool designedfor soft materials

Parts may stick in the tool if it is notdesigned/modified for DuPont™ ETPV

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Tool Design—Ejection

Sprue Design—Hot sprue and runner if possible, otherwise:Taper 3° to 5°

Short

Semi-Polished

Semi-Permanent Surface Treatment*

Tool DraftAmple 1° to 2°

Tool SurfaceTextured or Matte Surface (24 Charmilles)


EjectorsAir aided ejection

Ejector plaques and sleeves


* Balinit® Futura, a Titanium Aluminum Nitride treatment (by Balzers, Inc).

Balinit® is a registered trademark of Balzers, Inc.

* Please contact DuPont for recommendations on tool surface treatment.

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Grade X Flow I Flow

60A01 1.4% 4.7%

80A01 1.2% 2.3%

90A01 1.4% 1.5%

Tool Design—Mold shrinkage

*ISO 294-4 60x60x2 mm plaques at recommended molding conditions

Shrinkage influenced by:Material gradeMolding conditionsPart geometry

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Agenda

Why DuPont™ ETPV





1

5

Summary7


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Processing

Dry Material

Max recommended moisture content for processing: < 0.08%

Desiccant dryer; 2–4 hours at 80°C (175°F)

Purge Press

With low or high density PE

Five Stages of the Molding Cycle

Heat

Flow

Form

Cool

Eject

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Processing—Heat/Melt the Plastic

High viscosity and shear

Can use GP screw

Verify ability to maintain barrel set points

Low backpressure: 1–2 MPa (<300 ppsi)

Measure plastic (melt) temperature

240–250 (465–480)80A, 90A

250–260 (480–500)60A, 70A

Melt T °C (°F)Grade

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Processing—Flow/Move the Plastic

Fill part 99% full using speed control

Transfer on position

Slow speed 15–50 mm/s (0.6–2.0˝/s)

Melt being injected

Flow length of DuPont™ ETPV90A01 NC010 60A01LNC010

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Processing—Form/Pack and HoldDecreasing pressure profile 60–25 MPa (8700–3600 ppsi)

6 s hold time per 1 mm wall thickness

Room

DoorCorridor

Filling

Crystallization order

Put more material in to avoid internal voids.

Door and corridor have to be kept open.

Packing and Holding

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Processing - Form/Pack and Hold -Runner and Gate Recommendations

Cold runner is acceptable

Fan, diaphragm or “crystalline” design

Hot runner is preferred

Gate stays open longer

No demolding sprue

No specific issues with

thermal stability

wear due to filler

T = the thickest section of the partD = 1.2 x Td = 0.8 x T*gate land = 1 mm (maximum)

Tunnel “Crystalline” Design

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Processing—Cool and Eject

Mold temperature 30–60°C (86–140°F)Run higher temperatures for parts requiring good dimensional stability(higher temperatures result in better crystallinity)

Lower temperatures result in faster set up for ejection

Part out of the mold looks goodbut it has poor crystallinity

Part is deformed due topolymer recrystallization

Exposure to time and temperature

0.2465

0.5940

Post Anneal Shrink (%)Mold Temperature (°C)

90A01 NC010

*Plaques annealed for 2 hr at 100°C

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Processing Summary—5 Step Injection Molding Process

0—DRY MATERIAL

Max recommended moisture content for processing: < 0.08%

Desiccant dryer; 2–4 hours at 80°C (175°F)

1—HEATHigh viscosity and shearLow backpressure: 1–2 MPa (<300 ppsi)

Measure plastic (melt) temperature

2—FLOWFill part 99% full using speed controlTransfer on positionSlow speed 15–50 mm/s (0.6–2.0˝/s)

240–250 (465–480)80A, 90A

250–260 (480–500)60A, 70A

Melt T °C (°F)Grade

3—FORMPack and hold under decreasing pressure 60–25 MPa (8700–3600 ppsi)6 s hold time per 1 mm wall thickness—design gate to stay open this long

4—COOL

Mold Temperature 30–60°C (86–140°F)

Recommend higher temperatures for improved dimensional stability

5—EJECT

Recommend hot sprue and runner

Recommend textured and treated tool surface

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Processing—Troubleshooting

Problem Suggested Solution

Bridging in feed throat Reduce temp of rear zone

Short shots Increase injection stroke, time, pressure

If machine is at max injection pressure, increase barrel temperature

Check nozzle, sprue, runner & gates for frozen material / flow restrictions

Verify cycles are consistent

Flash Verify clamp pressure & no obstruction in mating surfaces of mold

Reduce shot size, pack pressure, melt temperature

Difficulty ejecting Decrease pack pressure, melt temperature, mold temperature

Increase fill time, cycle time

Part deformation Decrease pack pressure

Increase fill speed, cycle time

Shrinkage/sink marks Increase material in cavity: Increase pack time & pressure, shot size

Improve crystallinity: increase melt & mold temperature, injection speed

Degradation Reduce barrel temperature, hold up time, check for hold up spots

Verify material moisture & drying conditions

Weak weld lines Increase melt & mold temperatures, injection speed

Delamination Increase melt & mold temperatures

Increase or decrease pack pressure

Bulge at gate Reduce pack pressure, use decreasing hold pressure profile

Irregular surface bumps Increase nozzle temperature, verify adequate cold slug well

Flow lines Increase or decrease melt temperature & injection speed

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Agenda

Why DuPont™ ETPV





1


Summary7

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Current Applications

DuPont™ ETPV can be processed by standardthermoplastic processing techniques including:

Injection molding

Extrusion

2K Injection molding

Blow molding

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Agenda

Why DuPont™ ETPV





Summary6

1

7


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Summary

DuPontTM ETPV offers significant opportunities for part costreduction in high performance applications.

Critical factors for success include:

Material Selection

Part Design

Tool Design

Process Optimization

Maximize opportunity for program success…engage your DuPont representative at program launch.

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Thank you for joining us today.Please send in any questions using the Q&A function.

We will be answering questions for the rest of the hour. Depending on demand,we may not be able to answer your question straight away.All questions will be logged and any questions unanswered at the end of thesession will be followed-up via email.Alternatively, please contact your local DuPont representative or log on toplastics.dupont.com and click on the Contact Us button.

For questions about our products and how to use them,call us at the following numbers:800-441-0575 or International 302-999-4592

Or visit us at: plastics.dupont.com

Copyright © 2006 DuPont or its affiliates. All rights reserved. The DuPont OvalLogo, DuPont™, The miracles of science™, Kalrez®, Viton®, Vamac®, Hypalon®,Hytrel®, Crastin®, Rynite®, Thermx®, Zytel®, and Delrin® are registeredtrademarks or trademarks of DuPont or its affiliates.

dupont etpv web seminar - engpolymer.co.kr · dupont™ etpv and cross-linked rubbers astm d2000 /...

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