Desmopan (TPU)

Processing and machining

Plastics Business Group

Contents

1. 2.

Product description
The main advantages of Desmopan

4
5

General remarks
2.1 2.2 2.3 2.4 2.5 2.6 2.7 Form supplied Storage Pre-treatment of the granules Post-treatment of the finished articles Coloring Additives Occupational hygiene and environmental information 2.7.1 Air extraction 2.7.2 Waste disposal

6
6 6 6 8 8 9 9 9 9

3.

Processing by injection molding

3.1 General 3.2 Processing parameters 3.2.1 Temperature settings for cylinder and mold 3.2.2 Plastication 3.2.3 Injection pressure, holding pressure, back pressure, injection speed 3.2.4 Cycle times 3.2.5 Demolding 3.3 Regrind usage

10
10 12 12 13 14 14 15 15

4.

Tools for injection molding

4.1 4.2 4.3 4.4 4.5 4.6 4.7 Mold design Gating Hot runner technique and hot runner nozzles Flow characteristics of the mold Mold venting Shrinkage Demolding 4.7.1 Cavity surface 4.7.2 Drafts 4.7.3 Ejectors 4.8 Defects in injection molding

16
16 16 19 22 22 23 24 24 24 24 25

5.

Processing by extrusion
5.1 General 5.2 Screw design 5.3 Processing parameters 5.3.1 Temperature setting for the barrel and die 5.3.2 Screw speed 5.4 Adapters and extrusion dies 5.4.1 Adapters 5.4.2 Melt pump 5.4.3 Extrusion dies 5.5 Cooling and calibrating the extrudate 5.6 Extruded articles 5.6.1 Tubing 5.6.2 Sheathing of electric cables, ropes and connecting hoses 5.6.3 Profiles 5.6.4 Flat film 5.6.5 Blown film 5.6.6 Extrusion coating 5.6.7 Coextrusion 5.6.8 Extrusion blow molding 5.7 Defects in extrusion

26
26 28 30 30 30 31 31 31 32 34 34 34 36 36 37 37 38 38 38 39

6.

Machining and fabrication

6.1 Bonding 6.2 Welding 6.2.1 Hot air and nitrogen welding 6.2.2 Hot plate welding 6.2.3 Heated tool and heat impulse welding 6.2.4 High-frequency welding 6.2.5 Friction welding 6.2.6 Vibration welding 6.2.7 Ultrasonic welding 6.3 Machining 6.3.1 Sawing 6.3.2 Drilling 6.3.3 Turning 6.3.4 Milling and planing 6.3.5 Punching 6.3.6 Thread cutting

40
40 40 40 40 40 41 41 41 41 42 42 42 42 43 43 43

7. 8.

Index Range of products and Bayer service

44 46

1.

Product description

Desmopan

is the trade name for Bayers

range of thermoplastic polyurethanes (TPUs). On the basis of its excellent property profile, Desmopan can be categorized as a high-grade thermoplastic elastomer (TPE), bridging the gap between rubber and traditional thermoplastics.

Desmopan, the link between rubber and plastic

100

101 70A

102 75D

103

104 Shore hardness

Elasticity modulus MPa

Rubber Desmopan Polyamid 6 and 66 ABS PC POM PA-GF; PC-GF

The main advantages of Desmopan

High abrasion resistance High elasticity over the entire hardness rang Excellent low-temperature impact strength Flexibility over a wide temperature range Freedom from plasticizers Excellent resistance to oils, greases and many solvents Good resistance to weathering and high-energy radiation Pleasant tactile properties Weldable and bondable Easy coloring Easy recycling Excellent rot resistance (special grades)

2.

General remarks

Desmopan can be processed on the equipment normally used for processing thermoplastics. The most important processing techniques are: Injection molding Extrusion Blow molding

2.1 Form supplied

Desmopan is supplied as natural colored cylindrical or lentil-shaped granules. Depending on the particular grade, the color ranges from transparent/clear and whitish opaque to white. The product can be supplied in quantities of between 25 kg and 1,000 kg, depending on the grade. For sampling purposes, steel drums with a content of 30 kg can be supplied.

2.2 Storage
Desmopan should be stored in cool, dry conditions. Temperatures above 40 C should be avoided. Optimum processing is ensured within approx. 6 months after delivery.

2.3 Pretreatment of the granules

TPU absorbs moisture from the air. The extent and rate at which this happens depends on the raw material type, hardness and climate (Figs. 1 and 2).

Fig. 1

Moisture absorption of Desmopan granules (at 23 C/50 % r.h.)

0,6 % Moisture content 0,4 0,3 0,2 Ether-based

Ester-based

0,1
0 0
Fig. 2

1 1

3 4 Storage period

Days

0,10

%
Moisture content 0,06 0,05 0,04 0,02 0 0 2 4 6 8 10 Storage period 12 min 16

Ether-based Desmopan Ester-based Desmopan Threshold value for optimum processing

To ensure trouble-free processing and avoid any loss of quality, we recommend drying to a moisture content of 0.05 %. If the granules are too moist, blisters or streaks can occur on the surface of the finished components. The extrudate is no longer smooth and glossy but foamy and gassy. A frequent cause of defects is also the use of undried functional concentrates. These batches should be separately pre-dried and have a moisture content 0.05 %. Such levels can be reliably reached in conventional dry air and circulating air dryers (Fig. 3). Depending on the hardness, the recommended drying temperatures are between 80 and 110 C, with drying times of 1 to 3 hours. Better drying can be achieved in a shorter time with dry-air dryers (Fig. 4). Dried, hot granules should not be left to cool down in the open air. They must be stored in dry containers that can be re-sealed. The machine hopper must be kept covered over.

Operation of a dry-air drier

Fig. 3

A = Dry air B = Return air C = Fresh air D = Waste air

Fig. 4

Drying kinetics for Desmopan granules

0,20 % 0,16 0,14 0,12 0,10 0,08 0,06 0,05 0,04 0,02 0

Moisture content

15

30

45

60

75 90 Drying time

105

120

min

150

2.

General remarks

2.4 Post-treatment of the finished articles

TPU products attain their optimum physical property level only after they have spent some time at room temperature. This process can be speeded up by an annealing process in a circulating air heating oven, reducing it to 15 - 20 hours. For articles with a hardness of 92 Shore A, we recommend annealing at 80 - 90 C, and for a hardness of 93 Shore A, 100 110 C. The optimum compression set can only be reached by annealing! The physical data given in our data sheets are always measured on annealed, conditioned test specimens.

2.5 Coloring
Desmopan is supplied in its natural color. Coloring is a simple process and can be carried out by the processor himself. Coloring with masterbatches using Desmopan as the carrier material is both straightforward and reliable.

Masterbatches based on polystyrene and SAN resin have limited suitability, while those based on polyolefins and PVC are unsuitable. Desmopan can also be pigmented with pigments and pastes. The necessary additions will depend on the wall thickness of the articles, the color strength of the pigments and the specified color density: Normal additions are: Pigment masterbatches 1.0 - 4.0 % Color pastes 0.5 - 1.0 % Pigments 0.2 - 0.5 %

For occasional coloring, use rolling drum mixers or tumble mixers or similar. It is important to ensure that the colorants and other additives do not contain any moisture. A static mixer in the die will significantly improve color dispersion and also reduce the amount of colorant needed.

2.6 Additives
To improve the processing characteristics or specific properties, we recommend the addition of conventional functional concentrates such as antiblocking agents release aids UV stabilizers, which must also be pre-dried.

2.7 Occupational hygiene and environmental information

2.7.1 Air extraction
Desmopan can be machined and processed over a wide temperature range but, as with all natural and synthetic organic materials, it decomposes above a certain temperature. Smoke generation signifies that decomposition is taking place. Slow decomposition commences at approximately

240 C, depending on the grade of Desmopan involved. Further information is given in our Safety Data Sheets. For reasons of occupational hygiene, we recommend efficient air extraction especially when extruding and welding.

2.7.2 Waste disposal

Providing it is not contaminated with other substances, Desmopan can be dumped on municipal landfills. It does not constitute a hazard to water. If the material can no longer be recycled, it should be incinerated in a waste incineration plant on account of its high calorific value.

3.

Processing by injection molding

3.1 General
Optimum processing of Desmopan is only possible on screw-type injection molding machines. Well plasticated, homogeneous melts can be produced with single-flighted threezone screws of normal length. If a high plasticizing capacity (throughput) is needed, longer screws can be used (Fig. 5).

Due to the high shear stress, short-compressionzone screws are unsuitable. The high plasticizing energy needed for TPU requires a high torque for the screw drive. Insufficient torque leads to fluctuations in the screw speed and thus to non-uniform homogenizing.

To a limited extent, higher cylinder temperatures may yield better results, although there is a risk of the material overheating. The nozzle and cylinder head should be designed in such a way that there are no dead corners in which the material can become lodged and thus become thermally damaged.

Non-return valve

Screw tip Designed to fit nozzle

Metering zone 4d

2.75 mm 3.50 mm 4.00 mm 4.50 mm

10

Accurate temperature control for the cylinder and nozzle heating system is essential. Care must be taken that the nozzle is heated evenly over its entire length. Only in this way can local over-

heating or possible freezing of the melt be prevented. Molten Desmopan is neither corrosive nor abrasive. For this reason, there is no need for any special steel alloy or armor-plating of the screw.

Injection molded gear shift knobs

Fig. 5a

Injection molding screw for processing Desmopan

Fig. 5

Compression = 2:1; Length 18-20 d 1D

Compression zone 6d

Feed zone 8 10 d

Flight depths for 45 mm Flight depths for 65 mm Flight depths for 85 mm Flight depths for 100 mm

5.50 mm 7.00 mm 8.00 mm 9.00 mm

11

3.

Processing by injection molding

3.2 Processing parameters

3.2.1 Temperature settings for cylinder and mold
Injection unit Desmopan should be processed at melt temperatures of between 190 and 220 C. With some hard grades, a melt temperature of up to 240 C may be needed. The melt temperature ranges for the individual Desmopan grades can be found in the relevant product information sheets. Fig. 6 shows guide values for the settings for cylinder and nozzle heating in relation to the Shore hardness.

Mold The mold temperature has a major influence on the quality of the surface and the demolding behavior. It also affects shrinkage and internal (frozen-in) stresses in the final component. Normally, mold temperatures of 20 - 40 C will be used, but with some modified Desmopan grades and with glass fiber reinforced Desmopan, mold tempera-

tures of up to 60 C will be needed to ensure optimum surface quality. With thick-walled articles, cooling down to approx. 5 C can bring a reduction in cycle time.

Temperature profile according to hardness range

Fig. 6

C 190 to 200 200 to 230 190 to 210 170 to 200 160 to 180 C 190 to 220 200 to 220 200 to 220 180 to 210 170 to 200 C 220 to 240 230 to 250 220 to 240 210 to 230 210 to 230
12

3.2.2 Plastication
For plastication, the speed should be selected in such a way that the peripheral velocity of the screw does not exceed 0.3 m/s. The metering stroke should be between 1 D and 4 D.

Fig. 7 shows the maximum speeds for various screw diameters. Practical experience has shown that a 30 - 75 % capacity utilization of the respective cylinder is beneficial.

If the shot volume is very low in relation to the capacity of the cylinder, the dwell time of the melt in the plasticating unit will be very long indeed. This could result in thermal damage to the melt (Fig. 8).

Fig. 7

Screw speed range as a function of diameter

200 min-1 160 140 120 Speed 100 80 60 40 20 0 30 90 60 Normal screw diameters mm 150 Speed at V = 0.2 m/sec Speed at V = 0.3 m/sec

heated 20 - 40 C

Fig. 8

Breakdown of the TPU melt in the processing cylinder at a melt temperature of 220 C
40 TPU 90 Shore A 500 % Elongation at break MPa Tear strength 400 350 30 300 250 25

Shore hardness

70 to 85 Shore A 85 to 95 Shore A 35 to 50 Shore D 50 to 74 Shore D

0 1 2

Elongation at break Tear strength

20

200

5 10 15 min Dwell time of the melt in the cylinder

13

3.

Processing by injection molding

3.2.3 Injection pressure, holding pressure, back pressure, injection speed

For perfect processing, stepless control of the pressures and injection speeds is essential. It should be possible to regulate the injection and holding pressure in a range from 100 to 1,200 bar. The back pressure needed for homogenization is normally set at between 5 and 15 bar. The injection speed will depend primarily on the wall thickness. In general, thick-walled articles

require slow filling of the mold, and thin-walled articles fast filling. Apart from the wall thickness and type of gating, the venting of the mold plays an important role for the injection speed. This helps to avoid so-called burn marks caused by highly compressed hot air. The biggest influence on the dimensional stability and demoldability of the component is exerted by the injection pressure/ holding pressure. Excessive injection pressure overloads the molding, while too low a holding pressure produces sink marks.

Overloaded moldings are more difficult to demold. It is advisable to work with staggered pressures, with the holding pressure being set lower than the injection pressure. As a rule, a holding pressure of 50 % of the injection pressure will be adequate. This enables articles to be produced with a minimum of internal stresses. Fig. 9 shows a typical cycle.

3.2.4 Cycle times

The cycle time is governed by the shape of the article, the wall thickness, the cooling of the mold and the material itself. Fig. 10 shows how the wall thickness affects the duration of an injection cycle, measured for three grades of Desmopan: hard, medium and soft.

Cycle sequence in Desmopan processing

Pressure in front of the screw tip (bar)

Guide values for the individual pressure phases Injection pressure1) 300 - 1,200 bar 1) Holding pressure 100 - 500 bar 2) Back pressure 5 - 30 bar
1)

Injection pressure1)

2)

= melt pressure = control pressure of the hydraulic system

Holding pressure1)

Injection time

Holding pressure time Cycle time (s)

Back pressure2)
Cooling time

Fig. 9

14

Cycle time as a function of wall thickness and Shore hardness

10

3.2.5 Demolding
soft

hard

medium

mm

0 0 20 40 60 80 100 120 140 160 180 s 220

Cycle time
Fig. 10

Desmopan reproduces mold detail very well indeed. Particularly with the soft TPU grades, this can lead to more pronounced wall adhesion. This must be taken into account when designing the mold. Release agents can be used as demolding aids. Silicone-based release agents such as Baysilone M have given good results here. Silicone-free release agents are also suitable but must be applied more frequently.

Wall thickness

3.3 Regrind usage

Tensile strength and elongation at break vs. number of moldings
60

MPa 40 30 20 10 Elongation at break Tensile strength

700 Elongation at break %

600

The clean, sorted scrap resulting from the processing of Desmopan can be recycled after appropriate treatment and drying. The proportion of recycled material should not, however, be more than 30 %. Fig. 11 illustrates the change in the mechanical properties of a selected Desmopan grade using 100 % regrind material each time.

Tensile strength

500

6
Fig. 11

4 3 Number of moldings

15

4.

Tools for injection molding

4.1 Mold design

Molds for Desmopan should be made of the same kind of steel as is used for molding thermoplastics. Simple molds for small production runs can also be made of aluminum alloys. For prototype trial molds, inserts of casting resin or pressure die-cast metal could even be used. The following types of mold are suitable for processing Desmopan: Two-plate mold Three-plate mold Split mold Positive mold Multi-daylight mold

4.2 Gating
The following types of gate are commonly used for Desmopan:

Edge gate Film gate Diaphragm gate Pinpoint gate Ring gate Sprue gate Tunnel gate Hot runner gate

Design of a sprue bushing

Fig. 12

Hard thermoplastics

The gates, runners and sprues should be 25 - 50 % larger than with hard thermoplastics (Fig. 12). Significant pressure drops in the gating system should be avoided.

Taper angle (4 )

Desmopan
Sprue length max. 150 mm 16

Runner cross sections

Fig. 13

Wrong
As far as the runners are concerned, the flow channel must be designed in such a way that the full diameter of the runner is used and that it is positioned in one or both halves of the mold (Fig. 13). In multi-cavity molds, e.g. two-plate or three-plate types, the runners should be arranged in such a way that the flow paths are all roughly the same length(Fig. 14).

Right

Runners for multi-cavity molds

Fig. 14

17

4.

Tools for injection molding

Pin-point gates must have a weakened point on the gate cross section to ensure a clean tear-off. Large pin-point gates must not involve any jetting, otherwise squeeze marks can occur on the component. With axially symmetric parts, it may be useful to work with ring-type or diaphragm gates to prevent the formation of flow lines. Mold filling and venting must be kept under tight control (Fig. 15). A film gate is an advantage with large flat, long parts, as the mold is optimally filled (Fig. 16). A tunnel gate is the best solution if the gating point is not visible (Fig. 17).

Gate forms
Fig. 15

Ring gate

Diaphragm gate

3 - 6 Pin-point or film gate

Weakened point 0.5 - 0.1 mm

Clothes hanger-type film gate

Cross section A-B

Fig. 16

18

Tunnel gate with lenticular feed

Fig. 17

4.3 Hot runner technique and hot runner nozzles

Hot runner feed systems are becoming increasing popular in the processing of thermoplastics. With Desmopan, too, this technique is being used more and more often. Fig. 18 lists some of the main criteria for this method.

Demands on the hot runner system

Fig. 18

1. Flow technology
Optimum rheological design:

2. Temperature control
Good temperature control and precise temperature measurement: - Adequate number of control circuits - Position thermocouple where max. temperatures occur - Good thermal separation between cold injection molding tool and hot runner - Uniform temperature over the entire length of the runner

3. Mechanical aspects
Factors to taken into account in the design of a hot runner: - Injection pressure - Clamping, sealing and bearing forces - Thermal expansion - Surface of runner polished - Runner diameter < 7 mm: Pressure increase - Runner diameter >11 mm: Long dwell time

- Minimal rise in temperaturedue to shear - Tolerable shear rates (at flow restrictions < 5,000 s-1) - Low pressure drop (open flow channels should be preferred to annular cross sections)

19

4.

Tools for injection molding

Hot runner nozzles

Type 1: Open nozzle Open nozzle without plastic insulating cap for direct gating
Not very common for processing TPU, because of poor thermal separation, resulting in shiners, haloing, sticking and material drooling (Fig. 19).
Fig. 19

Open nozzle with plastic

insulating cap The insulating cap and cooling system lead to better thermal separation (Fig. 20).

Fig. 20

Open nozzle with

torpedo The narrow annular slit leads to excessive shear. Normally unsuitable for TPU (Fig. 21).

Fig. 21

20

Type 2: Open nozzle with sprue

This system is used primarily for large molds (single/multiple cavity) The particular advantages of this construction are its low pressure losses and good thermal separation (Fig. 22).

Fig. 22

Type 3: Nozzle with needle valve

A clean gating point can be placed directly on the component. This gating system is characterized by effective heat insulation and low pressure losses (Fig. 23).

Fig. 23

Wrong

Right
21

4.

Tools for injection molding

4.4 Flow characteristics of the mold

The flow behavior of Desmopan is basically the same as that of other thermoplastics. The length of the flow path is dependent on the melt temperature, the wall thickness of the part to be filled, the injection speed and the rheological properties of the material. The injection speed can be varied according to the machine and the technical circumstances. Fig. 24 shows the flow path of Desmopan as a function of melt temperature.

Fig. 24

Length of flow path as a function of temperature

Specimen: Rectangular spiral mold, 2 x 10 mm Injection pressure: approx. 900 bar 220 C 200

rd re Ha Sho 96

Melt temperature

re ft So Sho 85

190 180

170 160

100

200

300

400

500

mm

700

Flow path

4.5 Mold venting

Particularly with thickwalled parts of Desmopan, good venting of the mold cavities is essential. At the parting line, grooves of 0.02 to 0.04 mm in depth and 5 mm in width have proved suitable (Fig. 25). If the area in which the air is compressed is not in the area of the mold parting line, adequate venting can also be achieved through pins and inserts with appropriate play.

Fig. 25

Venting guidelines

Ground channel for air venting

0.1 mm

Full venting

Mold Ventilating channels at intervals of approx. 30 mm

22

4.6 Shrinkage
It is only possible to fix the shrinkage data for mold design for thermoplastic polyurethanes within certain limits because the shape of the article, its wall thickness and the processing conditions all exert a significant influence on shrinkage. As a rough guide for mold design, a shrinkage of approx. 1 % can be assumed. Minor differences in size are balanced out by the good elastic deformability.

Comparison of the shrinkage ranges with Desmopan

Fig. 26

Desmopan
Hard Medium Soft R-TPU 0 0,2 0,4 0,6 0,8 1,0 % 1,4

Shrinkage
transverse longitudinal

Post-molding shrinkage is greater with soft Desmopan grades and thin-wall articles than it is

with hard grades and greater wall thicknesses. Fig. 26 gives an idea of the extent of overall shrinkage.

0.020.04 mm deep

Mold sealing area

23

4.

Tools for injection molding

4.7 Demolding
4.7.1 Cavity surface
A mold cavity surface roughness of 0.5 - 0.6 m reduces demolding forces and aids ejection with Desmopan resins.

4.7.3 Ejectors 4.7.2 Draft

Mold drafts should be at least 5, particularly for components made of soft Desmopan grades. Staggered draft improves release from the mold wall (Fig. 27). For TPU, the surfaces of the ejectors should be as large as possible to avoid any deformation of the finished article (Fig. 28).

The high elasticity of Desmopan allows the demolding of undercuts and hollow articles. Blow moldings can be blown off the core using compressed air (Fig. 29).

Fig. 28

Small round ejectors

Large-area ejectors

Wrong

Right

Draft
5

Fig. 27

Fig. 29

Compressed air

24

4.8 Defects in injection molding

Defect Possible causes

Streaks on the surface of the article

Granules damp (plasticated melt foams up); melt too hot (melt is of very low viscosity, blistering on the surface of the article)

Matt surface Distinct weld line

Melt too cold Melt too cold; injection speed too slow; mold temperature too low; too much external release agent

Squeeze marks and lines Flash

Jetting due to unsuitable mold design

Melt temperature too high, injection pressure too high; injection speed too high; locking force too low; mold cavity not tight

Sink marks

Holding pressure too low, holding pressure time too short; no holding pressure effect due to small gate cross section; air in the cavity; inadequate venting; excessive wall thickness differences on the part

Gas bubbles

Back pressure too low (air is entrained in the melt); overheated melt; granules damp

Separations

Melt temperature too low; impurities; incompatible blend of different TPU grades

25

5.

Processing by extrusion

Desmopan grades in the hardness range between 70 Shore A and 52 Shore D are particularly suitable for extrusion applications. The following products can be extruded from Desmopan:

5.1 General
Conventional thermoplastic processing machines and tools can be used in Desmopan extrusion. The downstream units must be optimized for the typical properties of TPU.

The Desmopan pellets and any functional concentrates must be dried before processing to a moisture content of 0.05 %. See Sections 2.3 and 2.5.

Tubing Cables Tubular film Profiles Sheathings Flat and blown film Blow moldings Coatings

Blending with regrind and combining of different batches is not recommended. Single-screw extruders are normally used for extruding Desmopan. Vented barrels are unsuitable. Heated, grooved feed throats (Fig. 30) ensure higher, more uniform throughput.

26

Molten Desmopan is neither corrosive nor abrasive, which means there is no need for a special steel alloy or armor-plating of the screw. The drive ratings shown in Fig. 31 should be adhered to. Any additional torque means that processing can be carried out at lower temperatures, making for higher dimensional stability of the emerging melt.

Fig. 30

Grooved feed throat

Fig. 31

Minimum drive rating as a function of screw diameter

90 kW

Drive rating

60

40 25 15 0 30 45 60 Screw diameter 90 mm 120

27

5.

Processing by extrusion

5.2 Screw design

Single-flighted three-section screws with a length of approx. 22 to 32 D and constant pitch have proved successful for processing Desmopan. Fig. 32 shows the features of a screw suitable for processing Desmopan.

Constant taper screws (PVC screws) and barrier screws (e.g. Maillefer system) can also be used. Short-compression screws are not suitable for processing TPU. Heating of the screw is not necessary. Shearing and mixing sections are not needed for homogenizing Desmopan, although it may be an ad-

vantage to use mixing sections if particularly high color dispersion is needed, for example with thin film or coatings. The shearing section (Fig. 33) and mixing section (Fig. 34) should be designed in such a way that the energy input is as low as possible. Dead spots must be avoided under all circumstances.

Extruder screw for processing Desmopan

Fig. 32

Compression

Metering zone 7-10 D 2.5 mm 3.0 mm 4.5 mm 6.0 mm

28

Compression zone 7-10 D Flight depths for 45 mm Flight depths for 60 mm Flight depths for 90 mm Flight depths for 120 mm

Spiral shear section

Fig. 33

Fig. 34

Toothed disk mixing section

3:1; Length 2232 D 1D

Feed zone 8-10 D 7.5 mm 9.0 mm 13.5 mm 18.0 mm

29

5.

Processing by extrusion

5.3 Processing parameters

5.3.1 Temperature setting for the barrel and die
The extrusion temperatures for Desmopan are in the range between 160 and 220 C. The melt temperature ranges for the relevant Desmopan grades can be found in the product information sheets. Fig. 35 gives approximate temperatures for heating the barrel and die. The level of gloss on the article surface can be influenced by the die temperature. Low temperatures produce matt surfaces and high temperatures glossy surfaces.

5.3.2 Screw speed

In addition to the temperature, the screw speed also exerts a major influence on the quality of the extrudate. Low screw speeds mean that the melt has to spend a long time in the extruder, with the result that it may become damaged by heat. Excessive screw speeds also lead to thermal de-

composition due to friction. Speeds of between 15 and 50 rpm are recommended for extruding Desmopan.

Temperature profile according to hardness range

Fig. 35

Heated 20 to 40 C

Shore hardness
170 to 210 180 to 220 170 to 200 180 to 210 170 to 200 180 to 210 170 to 200 180 to 210 170 to 210 180 to 220 170 to 200 180 to 210 170 to 190 180 to 200 160 to 180 180 to 200 70 to 92 Shore A 92 to 95 Shore A 40 to 53 Shore D

30

5.4 Adapters and extrusion dies

5.4.1 Adapters
It is important to have adequate controlled heating of the die adapters and connecting flanges. With unheated flanges, so much heat may be dissipated that the temperature in this area drops too heavily. The flow channels must be designed so as to encourage good flow (i.e. without any dead spots), and the cross section should be geared to the mass flow rate. In long adapters, static mixers have proved useful for maintaining transverse mixing as they ensure greater uniformity of temperature and color dispersion in the melt. The use of strainer disks with and without a screen pack is of course also a possibility (Fig. 36).

5.4.2 Melt pump

A microprocessor-controlled gear pump for the melt raises the output and improves overall quality in the extrusion of profiles or tubes of very low dimensional tolerance. The melt pump also compensates for any extruder-related problems such as output fluctuations and incorrect pressure/temperature ratios. The basic principle is

that the melt pump breaks down the extruder output into smaller, volumetrically controlled individual flows and conveys them at a very accurate rate.

Example of a strainer disk with a screen pack

Fig. 36

Melt

31

5.

Processing by extrusion

5.4.3 Extrusion dies

As far as the dies are concerned, the same flow and heating guidelines apply as for adapters. Desmopan can be processed with side-fed dies (Fig. 37), spider-type dies (Fig. 38), flat-film dies (Fig. 39) and flat-film coextrusion dies (Fig. 40). The tools must allow a uniform flow front and be equipped with an easily centered die with a parallel guide (die land).

Side-fed die (tubular film production)

Fig. 37

Spider-type die
Fig. 38

32

Coathanger-type manifold for flat-film die

Fig. 39

Flat-film die
Fig. 40

33

5.

Processing by extrusion

5.5 Cooling and calibrating the extrudate

When the melt leaves the die, it has low dimensional stability. It should therefore be cooled as close as possible to the die without influencing the temperature control at the head of the die. Water baths, water spray jets, air showers or a combination of these sys-

tems can be used for cooling. To prevent any deformation of the extrudate while still in a plastic state, cooling should be carried out gently. The length of the cooling section will depend on the type of article, wall thickness and take-off speed. The final temperature should be 40 C. Calibration systems such as sizing/draw plates, floating plugs and vacuum

calibration can only be used with TPU if a lubricating film builds up between the extrudate and the calibrating surface. Fig. 41 shows a vacuum low-friction calibrator.

5.6 Extruded articles

5.6.1 Tubing
Tubes can be manufactured from Desmopan either horizontally or vertically. The horizontal arrangement is usually selected where the pipes/tubes cannot be deflected around corners because of their hardness and size.

Low-friction calibration

Fig. 41

Mandrel

Die

V Vacuum

Water inlet

Water outlet

34

Vertical manufacture is recommended for the production of thin-walled tubular film that is wound up flat. So that the bubbles do not collapse on leaving the die and so that no dimensional fluctuations occur, a constant supply of calibrating air must be passed through the die to inflate the tube and keep it in shape.

Fig. 42 shows a tube extrusion line. When extruding thinwalled tubing, it is an advantage to pre-cool it intensively with air. The flow of air solidifies the surface so that the subsequent water cooling cannot make any marks on the tube (Fig. 43). For the take-off unit, conveyor belts or rubber-covered caterpillar take-off units give good results.

Pre-cooling with air

Fig. 43

Mandrel Die Tube

Air

Precooling

Fig. 42

Tube extrusion line

35

5.

Processing by extrusion

5.6.2 Sheathing of electric cables, ropes and connecting hoses

Dies extending beyond the head should be heated. The mandrel through which the product to be sheathed is passed should be adjustable in the axial direction to allow the surface quality of the sheath to be influenced. The actual sheathing process is carried out by the pressure or tubular process (Fig. 44). With the pressure technique, a non-circular substrate can be topped up to produce a circular cross section. With the tubular process, a coating of even thickness is applied, which largely adjusts to the given cross section. Adhesion of the Desmopan extrudate to the carrier material essentially depends on which sheathing process is used. Good ad-

hesive strength can generally be achieved by the pressure method. On the other hand, the tube/pipe extrusion method allows easy peeling off of the sheathing. By applying a vacuum to the mandrel, adhesion can be adjusted to suit requirements. It is important to have a dry, grease-free substrate, otherwise blistering and adhesion problems may occur. Fig. 45 shows a cable sheathing head.

5.6.3 Profiles
Desmopan can be used to extrude profiles with a wide variety of different geometries. The aim should be to keep the wall thickness as uniform as possible. With major variations in wall thickness, the cross sections of the die must be designed in such a way that a uniform melt front is formed.

Fig. 44

Sheathing dies

Fig. 45

Sheathing of electric cables

Pressure die

Tubular die
36

5.6.4 Flat film

Flat film extrusion is generally used for film thicknesses greater than approx. 0.5 mm. Both the chill-roll process and the take-off calender are suitable. In the case of the calender, the first flight land clearance must be adjusted so that the film is polished on both sides. If a matt surface is required, matted PTFE-coated rollers or rollers covered with silicone rubber should be selected. The roll temperatures should be between 5 and 40 C.

5.6.5 Blown film

With the blown film process, film can be produced with a thickness of between 0.02 and approx. 1 mm. The addition of functional concentrates (e.g. antiblocking agents) makes the entire handling process easier. Fig. 46 shows a blown film line.

Blown film extruder

Fig. 46

37

5.

Processing by extrusion

5.6.6 Extrusion coating

Woven and nonwoven fabrics can be coated with Desmopan. The film, extruded with a flat-film die, is applied directly to the substrate. A calender pol-

ishes and simultaneously bonds the still plastic melt film to the substrate. The level of adhesion differs from one substrate to another and can be improved with the aid of suitable adhesion promoters.

5.6.7 Coextrusion
Through the coextrusion of Desmopan with hard thermoplastics, the range of properties and the number of possible applications for the resultant articles can be extended. Desmopan improves the scratch resistance, has pleasant tactile properties and insulates against noise. The coextrusion process can also be used to apply hot-melt adhesives to flat and tubular film of Desmopan.

5.6.8 Extrusion blow molding

The production of blow moldings is possible with specially developed grades of Desmopan using familiar techniques. Either blown film dies or accumulator heads can be used. Fig. 47 shows extruded bellows components.

Extrusion blow molded bellows

Fig. 47

38

5.7 Defects in extrusion Defect

Material lacks homogeneity

Possible causes
Incorrect screw geometry; temperature too low; screw speed too high, use of regranulated scrap; different grades or batches mixed together; cold areas in the die or adapter Die too cold, granules moist, incompatible or damp masterbatch Deposits at the edge of the die; flash at the die, poor color distribution; lubricant Moisture, die land too long; lubricant; overheating Moisture; melt temperature too high; residence time too long Uneven cooling; poor wall thickness distribution; poor centering Melt temperature too low; poor pressure build-up in the die Uneven take-off speed; pulsating melt stream; poor centering; unfavorable die land Irregular feed of granules; incorrect melt temperature; lubricants Melt temperature too high; moisture Melt temperature too high Melt temperature too low; output too high

Rough surface

Surface striation

Streaky surface

Bubbles in the extrudate

Sink marks

Weld lines

Dimensional inaccuracies

Irregular conveying

Low melt stability Sticking or blocking

Melt fracture

39

6. Machining and fabrication

6.1 Bonding
For bonding Desmopan, the adhesives industry supplies suitable systems under a variety of names. Only a few solvents (including NMP, DMF, MEK) dissolve Desmopan to such an extent that it is possible to produce a bonded joint. These solvents are harmful to health and it is essential that the information given in the Safety Data Sheets be observed.

6.2 Welding
Desmopan components can be joined together by welding. Suitable methods include:

6.2.1 Hot air and nitrogen welding

When welding with hot air or hot nitrogen, the flow of gas (measured 1 cm in front of the nozzle) should have a temperature of 290 - 330 C. To increase the weld strength, it is advisable to solidify the plastic weld with a cooled pressure roller.

6.2.2 Hot plate welding

Hot plate welding is particularly useful for the buttwelding of profiles. Both surfaces are melted on plates heated to 290 - 330 C and joined together under pressure so as to produce a bead. This bead can, if necessary, be machined off after cooling.

Hot air and nitrogen welding Hot plate welding Heated tool and heat impulse welding High-frequency welding Friction welding Vibration welding
In all cases, an efficient extractor must be provided for any carbonization gases.

6.2.3 Heated tool and heat impulse welding

The heated tool and heat impulse welding methods are suitable primarily for thin-walled articles and film. Care must be taken with these processes that sufficient pressure is exerted on the two parts being joined until the weld has cooled.

40

6.2.4 Highfrequency welding

Desmopan can be joined very well indeed by highfrequency welding. 1 mm thick film can be welded perfectly on a 2 kW unit, and a weld strength of 70 - 95 % of the materials strength is achieved. Even with film of 2 mm thickness, the weld strength is still 40 - 60 %. The higher strength applies to soft Desmopan grades and the lower one to hard grades.

6.2.5 Friction welding

Axially symmetrical parts of Desmopan can be joined together by friction welding. With suitable apparatus, this process can also be used on the production line. Depending on the nature of the component and the holding device, the mean peripheral velocity of the rotating half of the component should be 300 500 m/min. The faces of the parts being welded should be melted so that a bead becomes visible on pressing them together. The resultant loss of length must

be established in preliminary trials and taken into account when dimensioning the component.

6.2.7 Ultrasonic welding

This welding technique is not recommended because of the high inherent damping of TPU. The strength of the welds is lower than with the other welding processes.

6.2.6 Vibration welding

Vibration welding is useful in cases where friction welding is unsuitable because of the shape of the article. It enables large parts of differing geometries to be welded securely to each other. Vibration welding can be used for parts to be joined either at an angle or straight.

41

6.

Machining and fabrication

6.3 Machining
Sharp cutting tools are needed for Desmopan. Hard Desmopan grades can be machined in the same way as polyamides, but with soft grades (< 90 Shore A), the tough, elastic nature of the material must be taken into account. Desmopan can be machined on the machines normally used for metal and woodworking. Excessive heat generation should be avoided and efficient removal of the shavings must be ensured. Tools of fast-cutting steel are suitable for machining Desmopan. The tools must cut and not exert pressure. With large cutting depths, cooling with compressed air or drilling oil emulsions may be necessary. The following recommendations can be given for the various mechanical processes.

6.3.1 Sawing
Conventional saws can be used, but, especially when sawing by hand, saw blades intended for wood usually give better results than metal ones. Only saws with crossed teeth should be used.

6.3.3 Turning
Clearance angle = 5 - 15. Effective tool side rake = 25 - 30 Cutting edge angle = 40 - 60. Cutting speed, hard Desmopan V = 100 - 150 m/min Cutting speed, soft Desmopan V = 300 - 500 m/min Advance velocity, s = 0.1 - 0.2 mm/rev. Tip radius = approx. 0.3 mm - 0.5 mm.

6.3.2 Drilling
Twist drills with reliefground cutting edges (clearance angle = 12 16) and a small twist angle (approx. 30) are recommended. Drill tip = 150 Cutting speed V = 40 - 50 m/min. Advance s = 0.01 - 0.03 mm/rev Care must be taken to provide adequate ventilation and to remove the shavings. Cooling may be necessary for deeper holes.

42

6.3.4 Milling and planing

Woodworking machines are also suitable for Desmopan.

Clearance angle = 5 - 15 Effective tool side rake = 15. Cutting speed V = approx. 1,000 m/min Advance up to 0.5 mm/rev

6.3.5 Punching
Harder types can be punched more easily and accurately. Average cutting speed: 50 - 100 mm/sec.

6.3.7 Grinding
Soft, ceramically bonded silicon carbide discs with a fine glass paper grain have proved successful for this purpose. The resultant dust must be effectively extracted.

6.3.6 Thread cutting

Thread cutting is possible with the hard Desmopan grades. The screw taps must be very sharp indeed and the pre-drilling hole should be approx. 0.1 mm larger than is usual with steel.

43

7.

Index

A Adapter

31 ff. Air extraction 9 Anti-blocking agents 9; 37 Armor-plating of the screw 11; 27 14 7 26; 37 40

D Defects in extrusion

B Back pressure
Batches Blown film Bonding

C Calender

38 Calibration 34 Capacity utilization 13 Circulating air dryer 7 Coextrusion 38 Color granules 8 Color pastes 8 Coloring 8 Connecting flanges 31 Constant taper screws 28 Cooling 12; 34 Cycle time Fig. 10, 12; 24 Cylinder head 10 Cylinder heating 12

Defects in injection molding Delamination see Separations Demoldability 14 Demolding aids 15 Demolding 15; 23 ff. Diaphragm gate 16; 18; Fig. 14 Die temperatures 30 Dimensional stability 14 Drafts Fig. 27, 24 Drilling 42 Drive rating Fig. 31, 27 Dry-air dryer 7; Fig. 3 Drying kinetics Fig. 4 Drying temperature 7 Dwell time 13

39 25

G Gas bubbles

25 Gates 16 Gating techniques 16 Gating types Fig. 15, 16; 19 Gloss 30 Grinding 43 Grooved feed bush 26, Fig. 30 40 Heat treatment (annealing) 8 Heated tool welding 40 High-frequency welding 41 Holding pressure 14 Hollow articles 24 Homogenizing 28 Hot plate welding 40 Hot runner feed system 16; 19 Hot runner nozzles 20 ff. Hot-air welding 40 Incineration Injection molding Injection pressure Injection speed Internal stresses 9 Fig. 6, 10 ff. 14 14; 22 14 6

H Heat impulse welding

Ejectors Fig. 28, 24 Electric circuit 36 Extruded articles 34 ff. Extrusion blow-molding 38 Extrusion coating 38 Extrusion temperatures 30 Extrusion 26; 28; 30 ff. Feed throat Fig. 30, 26; 27 Film gate 16, 18; Fig. 16 Flash 25 Flash 25 Flat film 37 Flow channels 31 Flow characteristics Fig. 24, 22 Flow cross-section 17 Flow length 22 Form supplied 6 Friction welding 41 Functional concentrates 7, 9; 26; 37

Lentil-shaped granules

44

M Machining

42 Mandrel 36 Material overheating 10 Melt pump 31 Melt stream 25 Melt temperatures 12; 22 Metering stroke 13 Milling 43 Mixing sections 28 Moisture absorption Fig. 1 Moisture 7; Fig. 1; Fig. 2; Fig 3 Mold cavity 17; 24 Mold design 16 Mold stability 27 Mold temperature 12 Mold venting Fig. 25, 22 Multi-daylight mold 16 Nitrogen welding Nozzle heating Nozzle Packaging Pastes Peripheral velocity Pigments Pin-point gate Planing Plasticating Plasticating energy Positive mold Processing parameters Processing parameters - extrusion - injection moulding Processing Profiles Punching 40 11 ff. 10 ff. 6 8 13 8 16 43 10 13 16

Recyclate Regrind usage Release aids Ring gate Runners

26 Fig. 11, 15 9; 15 16; 18; Fig. 15 16 ff.

30 12 6 36 43

Sample drums 6 Sawing 42 Scrap material Fig. 11, 15 Screw design 28 ff. Screw drive 10 Screw heating 28 Screw speed 13; 30 Separations 25 Shear stress 10 Shearing section 28 Sheathings 26; 36; Fig. 45 Short compression screws 28 Shot volume 13 Shrinkage Fig. 26, 23 Side-fed die Fig. 36 Sink marks 14; 25 Slit die Fig. 39, 40 Spider-type die Fig. 38 Spiral shear section Fig. 33 Split mould 16 Sprue bushing Fig. 12, 16 Sprue gate 16 Sprue Fig. 22, 21 Squeeze marks 25 Static mixer 8; 31 Storage 6; 8 Storage temperature 6 Strainer disks 31 Streaks 25; 39

Temperature control 11 Thermal decomposition 30 Thread cutting 43 Three-plate mold 16 ff. Three-section screw 10; 28 Toothed disk mixing section Fig. 34 Torque 10 Tube extrusion 34 ff. Tubes 26; 34 ff. Tunnel gate 16; 18; Fig. 17 Turning 42 Two-plate mold 16 ff. Ultrasonic welding UV stabilizers Vented barrel Venting 41 9 26 Fig. 25, 18; 22 15 14; 22; Fig. 10 9 25 40 ff. 40 ff.

U V

W Wall adhesion
Wall thickness Waste disposal Weld line Weld strength Welding

45

8.

Range of products and Bayer service

Range of products, KU Europe Plastics Business Group / Engineering Thermoplastics

Polycarbonates
Apec Makrolon Makrofol /Bayfol

(PC-HT) (PC) (PC)/(PC+PBT) blend

Polycarbonate with high heat resistance Polycarbonate Specialty films based on polycarbonate and polycarbonate blends Acrylonitrile/butadiene/styrene copolymer Styrene/acrylonitrile copolymer Blend of polycarbonate and acrylonitrile/ butadiene/styrene copolymers Blend of ABS and polyamide Blends of styrene/maleic anhydride and ABS Acrylonitrile/styrene/butyl acrylate copolymer Polyamide Polybutylene terephthalate

Styrenics
Novodur/Lustran ABS Lustran SAN Bayblend Triax Cadon

(ABS) (SAN) (PC+ABS) (ABS+PA) (SMA+ABS) blend (ASA+ASA) blend

Centrex

Polyamides and polyesters

Durethan Pocan

(PA6, PA66, Co-PA) (PBT)

Thermoplastic polyurethane
Desmopan/Texin1 (TPU) Thermoplastic polyurethanes

Bayer glass fibers

Chopped strands Milled fibers Rovings

Filler for
(PA, PBT, ABS, PC, PPS, PP, PF) (PA, PC, PP, PTFE, PU-RRIM) (GMT)

Polymer raw materials

Bisphenol A Caprolactam (BPA) (CPL) (Cast PA)

Product line of Bayer NA (Bayer Corp. USA)

46

Bayer Service for innovative solutions and successful applications in virtually all sectors.
All the engineering plastics developed at Bayer have the full know-how of our development, design and process engineering services behind them. For more information contact: Bayer AG KU-EU/Information Systems Customer Response Desk Gebude B 207 D-51368 Leverkusen Tel.: +49 214/30-2 16 16 Fax: +49 214/30-6 12 77 This is also the address to contact for any other information (brochures, reference data tables, Application Technology Information brochures/ATIs) on the plastics featured in this general product brochure, as well as details of custom-tailored grades developed for specific applications.

47

Bayer plastics on the Internet: http//www.plastics.bayer.com

This information and our technical advice - whether verbal, in writing or by way of trials - are given in good faith but without warranty, and this also applies where proprietary rights of third parties are involved. Our advice does not release you from the obligation to check its validity and to test our products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery. Unless specified to the contrary, the values given have been established on standardized test specimens at room temperature. The figures should be regarded as guide values only and not as binding minimum values. Kindly note that, under certain conditions, the properties can be affected to a considerable extent by the design of the mold/die, the processing conditions and the coloring. Order-Nr.: KU14202-0102e/6016177 Edition: 2001-02 Printed in Germany E ek 03

Bayer AG Plastics Business Group D-51368 Leverkusen