Santoprene™ TPV

Extrusion Guide and

Technical Solutions

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Content

• Introduction
• Safety of operations
• Processing equipment
• Extruder, screw, head, die
• Processing guidelines
• Drying
• Coloring
• TPV processing
• Start-up
• Downstream equipment
• Cooling, calibration and shaping
• Haul-off, cutting, winding
• Regrinding, cleaning up
• Complex profiles : metal coating, flocking, slip coating

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Introduction

• Santoprene™ TPVs are inherently easily and economically extruded

• Smooth and consistent surface
• Low-gloss rubbery appearance from soft grades

• TPV structure (vulcanized rubber dispersed in a plastic matrix) gives

• Excellent melt strength and low die swell for extrusion of complex profiles
• Straightforward die design and no / minimal calibration

• Melt viscosity dependent on applied shear - melt flow mostly controlled

by screw speed, head and die design and less by heat from the barrel

• Can co-extrude with each other and with POs – also special grades
• Bonding: co-extrude with non-PO materials (PA, ABS, textile, metal, etc.)
• New: physical/chemical foams, tailored surfaces and robotic extrusion

• Guidelines from observations and years of experience with processors

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Safety of operations

• Highest level of commitment from ExxonMobil Chemical

• Key safety guidelines

• Safety remains operator’s responsibility
• Follow recommendations from material suppliers and machinery
manufacturers
• Use equipment safety systems and wear proper personal protective
equipment
• Always purge acetal or PVC materials from equipment before processing
Santoprene™ TPV

• Refer to detailed information related to safe handling of Santoprene TPV

in MSDS available on dedicated website (www.santoprene.com)

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Processing equipment: extruder

• Select extruder size to match profile cross-sectional area and throughput

• 38 to 65 mm (1.5 to 2.5”) for <10 cm2 (1.55 in2)
• 90 to 115 mm (3.5 to 4.5”) for >10 cm2 (1.55 in2)
• Typical L/D= 24:1
• Longer for more output / melt homogeneity
• Motor size= 0.25kWh/kg (0.113kWh/lb)
• Speed controlled to 0.2% from 0 to 100 rpm
• Barrel diameter defines maximum output
• Output increases linearly with screw rpm
Typical Output of Santoprene™ TPV *
European Grooved Feed Section U.S. Smooth Bore Feed Section
Barrel Diameter, mm Output, kg/hr Barrel Diameter, in Output, lb/hr
30 15 to 20 1.5 25 to 50
45 60 to 85 2.5 130 to 160
60 100 to 150 3.5 250 to 300
90 225 to 300 4.5 350 to 500
*Assumes 24:1 L/D and <=100 rpm; varies with screw design and grade (hardness) of Santoprene TPV.
Specific gravity of all grades is <=1.0.

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Processing equipment: extruder

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Processing equipment: screw

• Medium to high shear

• TPV melt sensitive to shear rate
• Screw cooling not recommended
• Typical screw : GP PO design
• Compression ratio 2.5 to 3.5
• L/D between 24:1 and 30:1
• Special screws
• Mixing pins or Maddock for color
• Barrier + grooved barrel for high
output
• Especially soft TPV grades <75A
• Grooved barrel for feed zone (<4
L/D) - Cooled to avoid bridging
• Melt gear pump may help
consistency
• Processing and profile quality

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Processing equipment: head

• Relaxation zone
• Flow change: rotational to laminar
• Avoid decompression downstream
• Output consistency

• Breaker plate
• Holes ∅ 2 to 4 mm (0.08 to 0.16”)
• Orientates flow with screen pack

• Screen pack
• Typical 20, 40 and 60 mesh
• Coarse 20 mesh on breaker
• Protects die
• Does not filter impurities
• Homogenizes melt
• Higher shear/back pressure
• Better profile surface

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Processing equipment: die [1]

• Die purpose to provide desired dimension to profile

• Further streamlining of flow after screens/breaker plate
• Converging flow paths and no decompression (source of instability)
• Balanced die-plates for same melt velocity across profile at die exit
• Provides profile straightness

• Die needs melt at desired pressure and temperature

• Head back pressure >50 bar (725 psi) and <200 bar (2,900 psi)
• Gives good melt flow but avoids excessive melt temperature/degradation
• Melt temperature control via separate heating zones
• Head/barrel connection, adapter with screens and breaker, die
• Locate melt temperature probe at land of final die plate and flush to die wall

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Processing equipment: die [2]

• General die design

• Excellent melt strength and low die swell - due to TPV morphology
(vulcanized rubber dispersed in a plastic matrix)
• Melt strength allows drawdown - reduces profile dimensions
• Die swell - increases profile dimensions
• Shear rate has biggest effect on swell
• More shear gives more swell (given by die opening and melt velocity)
• Higher for harder than for softer TPV grades
• Allow greater drawdown or calibration
• Swell greatest in thickness (vs. width or length) - more so for harder grades
• Limited effect of melt temperature
• Oversizing of extrusion dies – allows for drawdown and die swell
Die Dimensions
Percent Oversize Soft Grades Percent Oversize Hard Grades
Wall Thickness
(<=80A Durometer) (>=87A Durometer)
<3 mm or 0.120” 0 to 7 5 to 10
3 to 6 mm or 0.120 to 0.240” 5 to 10 10 to 20
>6 mm or 0.240” 10 to 15 10 to 20

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Processing equipment: die [3]

• Balancing melt flow through the die

• Melt tends to flow through center of die
• Die balancing adjusts land lengths to ensure melt flows to all areas of die
• Same pressure drop across land plate and same melt velocity across die exit
• Ensures proper filling of corners and thinner sections

• Land length ratio

• Die land length: die gap thickness
• Nominally 5:1 (typically >1:1 and <10:1)
• Achieve same ratio for all part thicknesses
• Shorter land gives lower pressure drop
• Affects thickness of die land plate

• Hollow cross-sections
• Can create via support webs (spider legs) between outer and inner sections
• Streamline webs for good knit of melt
• Fewer webs gives fewer knit lines

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Processing equipment: die [4]

• Complex dies for single extrusion

• Profile thickness varies 0.5 to 3.0 mm (0.019 to 0.120”) with hollow section(s)
• Typical die plate 20 to 30 mm thick (0.787 to 1.180”)
• Hollow sections created via pins at rear of die fixed to bridge or support rib
• Streamline bridge/support as well as cone channeling melt from breaker to die
• Avoids decompression and dead zones that could give polymer degradation

• Extrusion dies for tubing

• Typically, tube diameter <70% of extruder barrel diameter
• Generates sufficient pressure in extrusion die
• Polyolefinic die design with parallel land length 25 to 50 mm (0.980 to 1.967”)
• Air flow inside tube via an air inlet pin through spider or breaker plate
• Air inlet holes on breaker plates with ∅ of 1 to 2 mm (0.039 to 0.078”)
• Die exit >125 mm (4.92”) from spider to eliminate turbulent flow

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Processing equipment: die [5]

• Die design for complex profiles

• Plate 1 (profile die): oversize die exit 10 to 15% vs. profile
• Plate 2 (separator die): match to entry of plate 1
• Oversize thinner parts 1.5 to 3 times at tips and 150 to 200% vs. profile area
• 0.3 to 0.5 mm walls at boundaries of different thickness parts of profile
• Plate 3 (flow control die): match to entry of plate 2
• Oversize thinner parts 200 to 400% vs. target profile area
• See TPV processing guidelines for modifications to balance and streamline

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Processing equipment: die [6]

• Co-extrusion dies
• Same principles as for single extrusion
• For 1st material, use 50 mm (1.96”) thick die plate and streamline to center
• For 2nd material, use another die plate and channel melt around 1st material
• Additional die plate of 25 to 50 mm (0.98 to 1.96”) thickness may be needed
to channel 2 polymer flows together depending on profile complexity
• Last die plate gives final profile configuration
• Accurate temperature control of die plates for optimal flow <215°C (420°F)
• For best adhesion, increase t° of softer material
• Closer to melt temperature of harder material

• Tri-extrusion dies
• Vs. co-ex add another 50 mm (1.96”) thick die plate for 3rd polymer
• Extra care with off-set extruders
• Screen packs, decompression zones, connection to extrusion die, flow paths
• Melt stagnation could completely unbalance flow in multiple-extrusion die

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Processing equipment: die [7]

• Metal type, surface and surface treatment for extrusion dies and heads
• Low Carbon steel - balanced machinability and hardness
• Typical grade: 0.38 C, 0.50 Si, 0.50 Mn, 13.6% Cr
• Die walls unpolished - die face <3 micron Ra
• Clean with brass tools - apply anti-corrosion spray
• Nitration - improves wear
• Nickel plating - improves corrosion and wear
• Chrome plating - superior corrosion but limited life due to porous structure

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Processing: drying

• Consistently dry material to avoid

• Surface defects
• Porosity/voids
• Surging/low melt strength
• Irregular profile edges

• Desiccant drying recommended

• Constant low dew point airflow
• >1.5 m3/min/kg (25 ft3/min/lb)
• 2 to 3 hours @ 80°C (180°F)
• Dew point -21°C (-5°F)

• Best practices
• Regrind - extended drying
• Colorant - separate drying

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Processing: coloring

• Santoprene™ TPV natural grades easy to color

• Color concentrates with PP or PE carrier – typically recommended

• Use similar viscosity to TPV for enhanced dispersion
• Specialty bonding grades may need alternate carrier

• Pure dry pigment or liquid colorants – not recommended

• Typically difficult to disperse

• Colorant may affect properties

• Weathering
• Physicals
• Surface appearance

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Processing: TPV material

• Most Santoprene™ TPVs process similarly

• Always dry TPVs before extrusion

• See separate drying recommendations

• Cool extruder feed throat

• To prevent pellet bridging and air entrapment in melt

• Barrel and die temperatures

• Depend on extruder L/D, screw design, TPV grade
• See extrusion guide for starting temperature profiles
• Target melt temperatures typically ~190 to 220°C (375 to 430°F)

• Optimize to lowest melt temperature giving good profile quality

• Maximizes output

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Processing: start-up

• Clean extruder before start-up

• Resin residues from die/head/screw can cause surface spots

• Special attention to cleanliness following use with other thermoplastics

• Thorough cleaning mandatory after Acetal or PVC as melt mixing
with Santoprene™ TPV leads to decomposition and release of toxic gases
• For other resins or TPVs, purging may be used with low MI grade of PP or
PE

• Set barrel and die temperatures to recommended starting profile

• Allow temperatures to reach set-point then maintain for 30’
• Maintain for additional 30’ when starting extruder with resin in barrel

• Start extruder with very low screw speed

• Wait until material exits die and check head pressure stays <200 Bar (2,900
psi)
• Then increase screw rpm to normal operating speed

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Downstream equipment: cooling

• Water spray and/or immersion may be used

• Santoprene™ TPV gives good shape retention
• Soft TPV (<87A) single-material profiles do not
usually need sizing/calibration but hard grades
or co- or tri-extrusions might

• Closed-loop water spray – preferred

• Best cooling when profile t° >100°C (212°F)
• Turbulent water spray converted to steam

• Cooling bath
• Line speed and maximum profile thickness dictate length typically 2 to 20 m
(7 to 66 ft)
• Cooling needed for hauling, cutting, winding
• Length minimized by multi-pass / multi-profile methods or reducing bath-to-
die distance
• At bath exit aim for profile t° <38°C (100°F)

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Downstream equipment: calibration

• For some shapes simply orientate die (thickest profile section to bottom)
• Allows profile to pass rollers, belts and keep shape for in-line cutting

• Simple rod guides may provide additional shaping

• Can be PTFE coated to minimize friction (especially for soft TPVs <87A)
• Can direct water spray at profile/rod interface for cooling/lubrication

• Full sizing fixture to be used for most challenging geometries

• Single plate design for simplest fixture (ca. 6 mm [0.240”] thick and 5%
oversize)
• Use horizontal plate split for easy start-up

• Calibration/shaping fixtures recommended for:

• Single durometer profiles >87A
• Multi-durometer profiles

• Profiles with metal inserts and limited polymer need little/no calibration
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Downstream equipment: haul-off

• Key for dimensional control of profile

• Typically pair of variable speed belts with adjustable gap

• Belts to exert just enough pressure for contact and no slippage

• Excess pressure may deform profile

• Constant speed control capability (±0.5%)

• Linear speed typically 2 to 10% higher than that of extrudate

• Ensures straightness

• Minimize drawdown
• Avoids residual stress, warpage, shrinkage, etc.

• Care with metal inserts

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Downstream equipment:
typical line speed

Extrusion Extruder Diameter Typical Line Speed

Product Centimeters Inches Meters / Minute Feet / Minute
Hose Cover 6.35 2.5 30 to 100 9.1 to 30.5
Profile 6.35 2.5 50 to 200 15.2 to 61.0
Sheet 11.43 4.5 1.0 to 1.5 0.30 to 0.46
Tubing 6.35 2.5 30 to 100 9.1 to 30.5
Wire Insulation 6.35 to 8.89 2.5 to 3.5 1000 to 10000 305 to 3050
Wire Jacketing 6.35 to 8.89 2.5 to 3.5 100 to 300 30.5 to 91.4

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Downstream equipment: cutting
and winding

• Cutting
• Especially for hardness of 87A or greater
• Allow for post shrinkage
• Shrinkage depends on drawdown, thickness and TPV grade
• Typically 0.5 to 0.7% for minimal drawdown and profile cut <35°C (95°F)
• Guillotine, fly knife or toothless travelling saw may be used
• Saw tooth cutters may leave rough edge so not recommended

• Winding
• Especially for tube, wire and cable or some soft profiles (<73A)
• Use low to no tension
• For thick profiles (>4 mm [0.16”]) use large core diameter (>1 m [3’])
• Cool profile to <35°C (95°F) before winding

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Downstream equipment: regrind
and cleaning

• Regrind
• Regrind from production scrap can be reused as TPV is thermoplastic
• Prefer grinder with rotational knives and blade clearance 0.15 mm (0.006”)
• Low rotor speed (100 to 400 rpm) for soft grades
• Drying of regrind strongly recommended prior to extrusion
• Keep scrap/regrind clean

• Cleaning
• Clean prior to start-up, especially if other material used previously
• Check residue eliminated from all areas from hopper to die
• Avoid contact in melt state between TPV and PVC or Acetal
• Good practice to dismantle extrusion dies and clean with brass tools
• Apply anticorrosion spray after cleaning
• Dismantling preferred but may also purge with PE or PP before and after run
• Reduce t° after shutdown to avoid degradation/burning

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Downstream equipment: complex
profiles

• Metal coating
• 3 methods to bond metal to TPV in-line:
• Adhesive applied to metal insert
• Pre-coated metal insert activated by heat
• Co-extruded tie layer

• Flocking
• Polyester or Polyamide fibers for low friction surface
• 2 methods to bond fibers to TPV in-line meet automotive requirements:
• Post die adhesive and electrostatic fiber projection
• Pre-flocked tape heat welded just before/after die exit

• Slip coating
• 2 methods used as alternate to flock for low friction/abrasion:
• Co-extruded thin layer of special TPV slip coat grade
• Primer/lacquer coating dried and cured on line

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Summary

• Always purge all equipment of Acetal/PVC thoroughly before use

of Santoprene™ TPV
• Carefully select processing equipment and operating conditions to best
match desired part performance and Santoprene TPV grade attributes
• Santoprene TPV inherently easy materials to extrude
• Both single and complex profiles
• TPV morphology gives excellent melt strength and low die swell
• Enables extrusion of complex profiles with straightforward die design
• Minimal or no calibration
• TPV offers design flexibility and processing benefits usually associated
with thermoplastics (regrind use, multi-material extrusions, etc.)

For troubleshooting and more information refer to Santoprene TPV

processing guidelines for extrusion of thermoplastic vulcanizates

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