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
Product Line Portfolio and Key Properties2
Part Design Considerations3
Tool Design Considerations4
Processing Considerations5
2
1
Summary7
DuPont™ ETPV Applications6
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Product LineStandard grades
60A01L NC010 60 Shore A, lubricated
70A01 NC010 70 Shore A
80A01 NC010 80 Shore A
90A01 NC010 90 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
Product Line Portfolio and Key Properties2
Part Design Considerations3
Tool Design Considerations4
Processing Considerations5
1
3
Summary7
DuPont™ ETPV Applications6
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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
Product Line Portfolio and Key Properties2
Part Design Considerations3
Tool Design Considerations4
Processing Considerations5
1
4
Summary7
DuPont™ ETPV Applications6
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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)
Semi-Permanent Surface Treatment*
EjectorsAir aided ejection
Ejector plaques and sleeves
Semi-Permanent Surface Treatment*
* 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
Product Line Portfolio and Key Properties2
Part Design Considerations3
Tool Design Considerations4
Processing Considerations5
1
5
Summary7
DuPont™ ETPV Applications6
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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
Product Line Portfolio and Key Properties2
Part Design Considerations3
Tool Design Considerations4
Processing Considerations5
1
DuPont™ ETPV Applications66
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
Product Line Portfolio and Key Properties2
Part Design Considerations3
Tool Design Considerations4
Processing Considerations5
Summary6
1
7
DuPont™ ETPV Applications6
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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.